U.S. patent application number 13/565345 was filed with the patent office on 2014-08-21 for laser systems and methods for the removal of structures.
The applicant listed for this patent is Ronald A. De Witt, Paul D. Deutch, Daryl L. Grubb, Sharath K. Kolachalam, Eugene J. Linyaev, Scott A. Marshall, Joel F. Moxley, Sam N. Schroit, Mark S. Zediker. Invention is credited to Ronald A. De Witt, Paul D. Deutch, Daryl L. Grubb, Sharath K. Kolachalam, Eugene J. Linyaev, Scott A. Marshall, Joel F. Moxley, Sam N. Schroit, Mark S. Zediker.
Application Number | 20140231085 13/565345 |
Document ID | / |
Family ID | 51350321 |
Filed Date | 2014-08-21 |
United States Patent
Application |
20140231085 |
Kind Code |
A1 |
Zediker; Mark S. ; et
al. |
August 21, 2014 |
LASER SYSTEMS AND METHODS FOR THE REMOVAL OF STRUCTURES
Abstract
There is provided high power laser systems, high power laser
tools, and methods of using these tools and systems for cutting,
sectioning and removing structures objects, and materials, and in
particular, for doing so in difficult to access locations and
environments, such as offshore, underwater, or in hazardous
environments, such as nuclear and chemical facilities. Thus, there
is also provided high power laser systems, high power laser tools,
and methods of using these systems and tools for removing
structures, objects, and materials located offshore, under bodies
of water and under the seafloor.
Inventors: |
Zediker; Mark S.; (Castle
Rock, CO) ; Grubb; Daryl L.; (Houston, TX) ;
De Witt; Ronald A.; (Katy, TX) ; Deutch; Paul D.;
(Houston, TX) ; Moxley; Joel F.; (Denver, CO)
; Marshall; Scott A.; (Houston, TX) ; Linyaev;
Eugene J.; (Magnolia, TX) ; Schroit; Sam N.;
(Littleton, CO) ; Kolachalam; Sharath K.;
(Highlands Ranch, CO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Zediker; Mark S.
Grubb; Daryl L.
De Witt; Ronald A.
Deutch; Paul D.
Moxley; Joel F.
Marshall; Scott A.
Linyaev; Eugene J.
Schroit; Sam N.
Kolachalam; Sharath K. |
Castle Rock
Houston
Katy
Houston
Denver
Houston
Magnolia
Littleton
Highlands Ranch |
CO
TX
TX
TX
CO
TX
TX
CO
CO |
US
US
US
US
US
US
US
US
US |
|
|
Family ID: |
51350321 |
Appl. No.: |
13/565345 |
Filed: |
August 2, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13222931 |
Aug 31, 2011 |
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13565345 |
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13211729 |
Aug 17, 2011 |
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13222931 |
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13347445 |
Jan 10, 2012 |
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13211729 |
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13210581 |
Aug 16, 2011 |
8662160 |
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13347445 |
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13403741 |
Feb 23, 2012 |
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13210581 |
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12543986 |
Aug 19, 2009 |
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13403741 |
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12544136 |
Aug 19, 2009 |
8511401 |
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12543986 |
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12706576 |
Feb 16, 2010 |
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12544136 |
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13366882 |
Feb 6, 2012 |
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12706576 |
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61514391 |
Aug 2, 2011 |
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61605422 |
Mar 1, 2012 |
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61605429 |
Mar 1, 2012 |
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61605434 |
Mar 1, 2012 |
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61378910 |
Aug 31, 2010 |
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61374594 |
Aug 17, 2010 |
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61431827 |
Jan 11, 2011 |
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61431830 |
Feb 7, 2011 |
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61446312 |
Feb 24, 2011 |
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61090384 |
Aug 20, 2008 |
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61102730 |
Oct 3, 2008 |
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61106472 |
Oct 17, 2008 |
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61153271 |
Feb 17, 2009 |
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61090384 |
Aug 20, 2008 |
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61102730 |
Oct 3, 2008 |
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61106472 |
Oct 17, 2008 |
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61153271 |
Feb 17, 2009 |
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61295562 |
Jan 15, 2010 |
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61439970 |
Feb 7, 2011 |
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Current U.S.
Class: |
166/288 ; 114/26;
219/121.67; 219/121.72 |
Current CPC
Class: |
B23K 26/12 20130101;
B23K 26/14 20130101; E02D 17/00 20130101; B23K 26/0096 20130101;
E21B 33/13 20130101; E21B 41/00 20130101; B23K 26/1224 20151001;
B23K 26/1464 20130101; B63B 17/00 20130101; E21B 19/002 20130101;
B23K 26/064 20151001; B23K 26/106 20130101; E02B 2017/0052
20130101; B63B 19/00 20130101; B23K 26/127 20130101; B23K 26/00
20130101; B23K 26/04 20130101; B63B 21/00 20130101; B23K 26/0652
20130101; B63B 35/28 20130101; E21B 29/02 20130101; B23K 26/38
20130101; B08B 7/0042 20130101; B23K 2103/10 20180801; B63B 35/00
20130101; B23K 26/146 20151001 |
Class at
Publication: |
166/288 ;
219/121.72; 219/121.67; 114/26 |
International
Class: |
B23K 26/12 20060101
B23K026/12; B63B 35/28 20060101 B63B035/28; E21B 33/13 20060101
E21B033/13; B23K 26/00 20060101 B23K026/00; B23K 26/38 20060101
B23K026/38 |
Claims
1. A method of removing a section of a member from an offshore
structure comprising: a. operably associating a high power laser
system with an offshore structure, the high power laser system
comprising a high power laser and a high power laser cutting tool;
b. the high power laser cutting tool defining a laser beam delivery
path for delivery of a high power laser beam along the beam path;
c. positioning the laser cutting tool adjacent a member of the
offshore structure, whereby the laser beam path extends from the
cutting tool to the member; d. propagating a high power laser beam
along the beam path and moving the beam path and laser beam thereby
cutting the member, whereby a section of the member is formed in a
predetermined manner; and, e. removing the section from the
structure.
2. The method of claim 1, wherein the member is located below a
surface of a body of water.
3. The method of claim 1, wherein the member is a tubular and the
cut is an inside-to-outside cut.
4. The method of claim 1, wherein the member is a tubular and the
cut is an outside-to-inside cut.
5. The method of claim 1, wherein at least a portion of the member
is located above a surface of a body of water.
6. The method of claim 1, wherein at least a portion of the member
is located below a sea floor.
7. The method of claim 1, wherein at least a portion of the member
is in a sea floor.
8. The method of claim 1, wherein the laser beam path is positioned
in a body of water.
9. The method of claim 1, wherein the laser beam path is positioned
below a sea floor.
10. The method of claim 2, wherein the laser beam propagated along
the beam path is at least about 5 kW.
11. The method of claim 3, wherein the laser beam propagated along
the beam path is at least about 10 kW.
12. The method of claim 4, wherein the laser beam propagated along
the beam path is at least about 15 kW.
13. The method of claim 1, wherein the laser beam propagated along
the beam path is at least about 5 kW.
14. The method of claim 1, wherein the laser beam propagated along
the beam path is at least about 10 kW.
15. The method of claim 1, wherein the high power laser system
comprises a laser cutting platform that is positioned above a
surface of a body of water; the laser cutting platform, comprising:
an operably associated device for hoisting; an operably associated
laser cutting device for cutting; and, an operably associated
device for holding; wherein the operably associated laser cutting
device defines a second beam path; and, propagating a laser beam
along the second beam path.
16. The method of claim 15, wherein the laser beam propagated along
the cutting tool beam path is at least 5 kW and the laser beam
propagated along the second beam path is at least 5 kW.
17. The method of claim 1, comprising hoisting the section from a
body of water.
18. The method of claim 1, comprising hoisting the section from
below a sea floor.
19. The method of claim 1, comprising verifying completion of a cut
prior to removing the section.
20. The method of claim 19, wherein the verifying is passive.
21. The method of claim 20, wherein the verifying is real-time and
based at least in part on monitoring the laser beam.
22. The method of claim 19, wherein the verifying is based at least
in part on laser range finding.
23. An offshore method of cutting material associated with an
offshore structure comprising: a. positioning a high power laser
system over a body of water and proximate to a location of an
offshore structure, the high power laser system comprising a high
power laser and a high power laser cutter assembly; b. the high
power laser cutter assembly defining a laser beam delivery path for
delivery of a high power laser beam along the beam delivery path;
c. propagating a high power laser beam along the beam delivery
path, the laser beam having a power of at least 5 kW; and, d.
changing a relative position of a material to be sectioned and the
laser beam path in a predetermined laser beam delivery pattern,
whereby the laser beam cuts the material in a predetermined
cut.
24. The method of claim 23, wherein the predetermined delivery
pattern is a continuous ring around the circumference of a
tubular.
25. The method of claim 23, wherein the predetermined cut is a pair
of openings for affixing a lifting device.
26. The method of claim 23, wherein the predetermined cut is a
complete cut.
27. The method of claim 26, comprising passive verification of the
complete cut.
28. The method of claim 27, wherein the passive verification is
real-time and based at least in part on monitoring the laser
beam.
29. The method of claim 27, wherein the passive verification is
based at least in part on laser range finding.
30. The method of claim 23, wherein the laser beam propagated along
the beam path strikes a platform jacket member.
31. The method of claim 23, wherein the laser beam propagated along
the beam path strikes a platform jacket member in a circular
pattern.
32. The method of claim 23 wherein the laser beam propagated along
the beam path strikes a platform pylon in a circular pattern.
33. The method of claim 23, wherein the predetermined pattern
comprises a land area and a cut area.
34. The method of claim 23, wherein the predetermined pattern
comprises a single pass pattern of beam delivery, wherein the laser
beam completely severs the material in a single pass of the laser
beam.
35. The method of claim 23, wherein the laser beam is delivered in
a predetermined beam delivery pattern comprising a substantially
vertical beam path.
36. The method of claim 23, wherein the laser beam is delivered in
a predetermined beam delivery pattern comprising a substantially
horizontal beam path.
37. The method of claim 23, wherein the laser beam is delivered in
a predetermined beam delivery pattern comprising a substantially
vertical beam path and a substantially horizontal beam path.
38. The method of claim 23, wherein the laser beam is delivered in
a predetermined beam delivery pattern comprising a substantially
axial beam path.
39. The method of claim 23, wherein the laser beam is delivered in
a predetermined beam delivery pattern comprising a substantially
radial beam path.
40. The method of claim 23, wherein the laser beam is delivered in
a predetermined beam delivery pattern comprising a substantially
axial beam path and a substantially radial beam path.
41. A method of cutting material associated with an offshore
structure comprising: a. positioning a high power laser system
proximate to an offshore structure in a body of water, the high
power laser system comprising a high power laser optically
associated by an umbilical with a high power laser cutter assembly;
b. the high power laser cutter assembly defining a laser beam
delivery path for delivery of a high power laser beam along a beam
path; c. positioning the beam path below a surface of a body of
water; d. propagating a high power laser beam along the beam path
below the surface of the body of water; and, e. changing a relative
position of a member to be cut and the laser beam path, whereby the
laser beam strikes the member below the surface of the body of
water and thereby cuts the member below the surface of the body of
water.
42. The method of claim 41, wherein the laser beam path when the
laser beam is propagated along the beam path is positioned below a
seafloor of the body of water.
43. The method of claim 41, wherein the laser beam path when the
laser beam is propagated along the beam path is positioned in a
mudline of the body of water.
44. The method of claim 41, wherein the laser beam path when the
laser beam is propagated along the beam path is positioned below a
mudline of the body of water.
45. The method of claim 41, wherein the offshore structure is an
oil platform.
46. The method of claim 41, wherein the offshore structure is a
jacket and pile structure
47. The method of claim 41, wherein the offshore structure is a
monopile structure.
48. The method of claim 41, wherein the offshore structure is a
pipeline.
49. The method of claim 41, wherein the offshore structure is a
bridge support.
50. The method of claim 41, wherein the member comprises an inner
steel tubular, and an outer steel tubular.
51. The method of claim 50, wherein the inner steel tubular and the
outer steel tubular define an annulus.
52. The method of claim 51, wherein the annulus is at least
partially filled with air.
53. The method of claim 51, wherein the annulus is at least
partially filled with a solid material.
54. The method of claim 53, wherein the solid material is
cement.
55. The method of claim 41, wherein the laser beam propagated along
the beam path strikes an inner tubular positioned within an outer
tubular and whereby upon completion of the cutting the inner
tubular is severed and the outer tubular is not cut by the laser
beam.
56. The method of claim 41, wherein the laser beam propagated along
the beam path strikes an inner tubular positioned within an outer
tubular and whereby upon completion of the cutting the inner
tubular is severed and the outer tubular is severed.
57. A method of plugging and abandoning a well using a high power
laser system, the method comprising: a. selecting a well that
extends below a surface of the earth, the well having tubulars
contained within the well and at least one tubular extending from a
location within the well below the surface of the earth to a
location above the surface of the earth; b. determining a
configuration of at least some of the tubulars; c. formulating a
plugging and abandonment plan for the well based in part upon the
configuration of at least some of the tubulars; d. the plugging and
abandonment plan comprising: cutting a tubular at a predetermined
location within the well and removing the tubular above the cut
from the well; placing a plug within the well; cutting and removing
all tubulars from the well at least about three feet below the
surface of the earth; and, e. performing the cutting with a high
power laser beam.
58. The method of claim 57, performing additional cutting of the
tubular with a high power laser beam.
59. The method of claim 57, performing additional cutting of the
tubular exclusively with a high power laser beam.
60. The method of claim 57, wherein the surface of the earth is a
sea floor.
61. A method of plugging and abandoning a well using a high power
laser system, the method comprising: a. selecting a borehole in a
surface of the earth forming a well, the borehole having a tubular
contained therein, the tubular extending below the surface of the
earth; b. placing a first plug within the borehole; c. cutting the
tubular at a location within the borehole and removing at least a
some of the cut tubular from the borehole; placing a second plug
within the borehole, the second plug being located closer to the
surface of the earth than the first plug; d. delivering a high
power laser beam along a beam path to cut all additional tubulars
within the borehole at a second location above the second plug,
wherein the delivery of the laser beam completely severs all the
additional tubulars at the location within the borehole; and, e.
removing all of the severed additional tubulars from the borehole
above the second location, wherein the borehole above the second
location is free from the additional tubulars.
62. The method of claim 61, wherein the second location is at least
about 3 feet below the surface of the earth and the surface of the
earth is a sea floor.
63. The method of claim 62, wherein the second location is at least
about 5 feet below the surface of the earth and the surface of the
earth is a sea floor.
64. The method of claim 63, wherein the second location is at least
about 10 feet below the surface of the earth and the surface of the
earth is a sea floor.
65. The method of claim 64, wherein the second location is at least
about 15 feet below the surface of the earth and the surface of the
earth is a sea floor.
66. A method of removing a conductor from a body of water using a
high power laser system, the method comprising: a. positioning a
high power laser cutting tool proximate a location on a conductor
below a surface of a body of water; b. directing a high power laser
beam along a beam path from the laser cutting tool to the location,
wherein the laser beam severs the conductor at about the location,
thereby creating a severed section of the conductor above the
location; and c. raising the severed section of the conductor above
the surface of the body of water.
67. A method of removing contamination from an offshore structure
to lessen the weight of the structure, the method comprising: a.
positioning a high power laser system over a body of water and
proximate to a location of an offshore structure, the high power
laser system comprising a high power laser optically associated
with a high power laser delivery assembly; b. the high power laser
delivery assembly defining a laser beam delivery path for delivery
of a high power laser beam along the beam delivery path; c.
positioning the beam delivery path between the delivery assembly
and a location of the offshore structure; d. propagating a high
power laser beam along the beam delivery path, the laser beam
having a beam property; e. scanning the high power laser beam from
a location on the offshore structure to a second location on the
offshore structure at a scan rate, whereby the beam property and
scan rate are such that contamination is removed from the offshore
structure without substantial damage to the offshore structure.
68. The method of claim 67, wherein the beam property is a power of
the beam.
69. The method of claim 67, wherein the beam property is a pulse
rate of the beam.
70. The method of claim 67, wherein the beam is pulsed.
71. The method of claim 67, wherein the beam property is a duty
cycle.
72. A method of removing large heavy offshore structures from a
body of water, without the need for heaving hoisting equipment, the
method comprising: a. positioning a high power laser system over a
body of water and proximate to a location of an offshore structure,
the high power laser system comprising a high power laser optically
associated with a high power laser delivery assembly; b.
determining a laser cutting plan for cutting the offshore structure
into sections of a predetermined size and weight; c. laser cutting
the offshore structure below a surface of the body of water into a
predetermined section; and, d. removing the predetermined section
from the body of water.
73. The method of claim 72, wherein a majority of the predetermined
sections are less than about 500 tons in weight.
74. The method of claim 72, wherein a majority of the predetermined
sections are less than about 200 tons in weight.
75. The method of claim 72, wherein a majority of the predetermined
sections are less than about 100 tons in weight.
76. The method of claim 72, wherein a majority of the predetermined
sections are less than about 50 tons in weight.
77. The methods of claim 72, comprising a laser beam having a
wavelength of greater than about 1000 nm to about 1550 nm.
78. A laser decommissioning, plugging and abandoning vessel
comprising: a. a vessel; b. a high power laser having at least
about 10 kW of power; c. a means for high power laser cutting; and,
d. a means for optically associating the laser and the means for
cutting
79. The laser vessel of claim 78, wherein the means for high power
laser cutting comprises a means for positioning a laser beam path
between the laser cutting tool and a member to be cut for making an
inside-to-outside cut.
80. The laser vessel of claim 78, wherein the means for high power
laser cutting comprises a means for positioning a laser beam path
between the laser cutting tool and a member to be cut for making a
outside-to-inside cut.
81. The laser vessel of claim 78, wherein the high power laser
propagates a laser beam having a wavelength of about 1060 nm to
about 2100 nm.
82. The laser vessel of claim 78, wherein the means for high power
laser cutting comprises a fluid laser jet nozzle.
83. The laser vessel of claim 78, wherein the means for high power
laser cutting comprises a total internal reflection prism.
84. The laser vessel of claim 78, wherein the means for high power
laser cutting comprises an anchoring means, a laser cutting head,
and a means for extending the laser cutting head from the anchoring
means.
85. The laser vessel of claim 78, comprising a means for laser
radar cut verification in association with the laser cutting
means.
86. The laser vessel of claim 78, comprising a means for passive
cut verification
87. The laser vessel of claim 78, comprising means for real-time
cut verification.
88. The laser vessel of claim 78, wherein the means for high power
laser cutting comprises a means for passive cut verification.
89. The laser vessel of claim 78, wherein the means for high power
laser cutting comprises a means for laser radar cut
verification.
90. The laser vessel of claim 78, wherein the vessel is a
barge.
91. The laser vessel of claim 78, wherein the vessel is a ship.
92. The laser vessel of claim 78, wherein the means for high power
laser cutting comprises a laser cutting tool.
93. A mobile laser removal system, capable of being placed on a
vehicle, vessel, platform, or offshore structure, the system
comprising: a high power laser having at least 5 kW of power; and,
a subsea high power laser cutting tool; and, an umbilical for
optically associating the high power laser with the subsea high
power laser cutting tool.
94. The mobile laser removal system of claim 93, comprising a laser
platform for raising and cutting severed members.
95. The mobile laser removal system of claim 93, comprising an
above the surface laser cutting device.
96. The mobile laser removal system of claim 93 comprising a laser
shop.
97. The mobile laser removal system of claim 95, being modular and
comprising a laser platform, an above the surface laser cutting
tool device, and a second laser cutting device.
98. The mobile laser unit of claim 95, wherein the high power
subsea laser cutting tool comprises a means for positioning a laser
beam path between the subsea laser cutting tool and a member below
a surface of the sea for making an inside-to-outside cut.
99. The laser unit of claim 95, wherein the laser cutting tool
comprises a means for positioning a laser beam path between the
laser cutting tool and a member to be cut for making a
outside-to-inside cut.
100. An underwater laser cutting tool, comprising: a laser tool
body defining a longitudinal axis and comprising a conveyance
termination section and an anchoring section; a stand-off distance
setting device, whereby the laser tool body axis may be positioned
in a predetermined location relative to an axis of a tubular to be
cut; a motor section; a laser cutting head section, comprising a
laser beam exit; and a laser optics defining an axis.
101. The underwater laser cutting tool of claim 100, wherein the
axis of the laser optics and the laser tool body axis are
coaxial.
102. The underwater laser cutting tool of claim 100, wherein the
predetermined location provides for the tool body axis to be
coaxial with the axis of the tubular.
103. The underwater laser cutting tool of claim 100, wherein the
predetermined location provides for the axis of the laser optics to
be coaxial with the axis of the tubular.
104. The underwater laser cutting tool of claim 101, wherein the
predetermined location provides for the tool body axis and the axis
of the laser optics to be coaxial with the axis of the tubular.
105. The underwater laser cutting tool of claim 100, comprising a
packer.
106. The underwater laser cutting tool of claim 100, comprising a
passage for handling returns.
107. The underwater laser cutting tool of claim 100, comprising a
gas laser jet nozzle.
108. The underwater laser cutting tool of claim 100, comprising an
extending section between the laser cutting head section and the
anchoring section, whereby the laser cutting head section is
capable of being advanced through mud, without the need for
dredging.
109. An offshore laser services system, capable of providing
offshore laser decommissioning, plugging, abandonment, cleaning, or
cutting services, the system comprising: a remote operated vehicle;
a laser module; an umbilical; and, a laser cutting tool; whereby
the system is capable of laser cutting offshore materials selected
from the group consisting of mooring chains, subsea pipelines,
jacket structures, piles, conductors, tubulars, and control
umbilicals.
110. The system of claim 109, comprising a second laser cutting
tool, comprising a means for fixedly associating the laser cutting
tool with a structure to be laser cut.
Description
[0001] This application: (i) claims, under 35 U.S.C.
.sctn.119(e)(1), the benefit of the filing date of Aug. 2, 2011 of
provisional application Ser. No. 61/514,391; (ii) claims, under 35
U.S.C. .sctn.119(e)(1), the benefit of the filing date of Mar. 1,
2012 of provisional application Ser. No. 61/605,422; (iii) claims,
under 35 U.S.C. .sctn.119(e)(1), the benefit of the filing date of
Mar. 1, 2012 of provisional application Ser. No. 61/605,429; (iv)
claims, under 35 U.S.C. .sctn.119(e)(1), the benefit of the filing
date of Mar. 1, 2012 of provisional application Ser. No.
61/605,434; (v) is a continuation-in-part of U.S. patent
application Ser. No. 13/222,931, filed Aug. 31, 2011, which claims,
under 35 U.S.C. .sctn.119(e)(1), the benefit of the filing date of
Aug. 31, 2010 of provisional application number Ser. No.
61/378,910; (vi) is a continuation-in-part of U.S. patent
application Ser. No. 13/211,729, filed Aug. 17, 2011, which claims,
under 35 U.S.C. .sctn.119(e)(1), the benefit of the filing date of
Aug. 17, 2010 of provisional application number Ser. No.
61/374,594; (vii) is a continuation-in-part of U.S. patent
application Ser. No. 13/347,445, filed Jan. 10, 2012, which claims,
under 35 U.S.C. .sctn.119(e)(1), the benefit of the filing date of
Jan. 11, 2011 of provisional application number Ser. No. 61/431,827
and the benefit of the filing date of Feb. 7, 2011 of provisional
application Ser. No. 61/431,830; (viii) is a continuation-in-part
of U.S. patent application Ser. No. 13/210,581, filed Aug. 16,
2011; (ix) is a continuation-in-part of U.S. patent application
Ser. No. 13/403,741, filed Feb. 23, 2012, which claims, under 35
U.S.C. .sctn.119(e)(1), the benefit of the filing date of Feb. 24,
2011 of provisional application number Ser. No. 61/446,312; (x) is
a continuation-in-part of U.S. patent application Ser. No.
12/543,986, filed Aug. 19, 2009, which claims, under 35 U.S.C.
.sctn.119(e)(1), the benefit of the filing date of Aug. 20, 2008 of
provisional application Ser. No. 61/090,384, the benefit of the
filing date of Oct. 3, 2008 of provisional application Ser. No.
61/102,730, the benefit of the filing date of Oct. 17, 2008 of
provisional application Ser. No. 61/106,472 and the benefit of the
filing date of Feb. 17, 2009 of provisional application Ser. No.
61/153,271; (xi) is a continuation-in-part of U.S. patent
application Ser. No. 12/544,136, filed Aug. 19, 2009, which claims,
under 35 U.S.C. .sctn.119(e)(1), the benefit of the filing date of
Aug. 20, 2008 of provisional application Ser. No. 61/090,384, the
benefit of the filing date of Oct. 3, 2008 of provisional
application Ser. No. 61/102,730, the benefit of the filing date of
Oct. 17, 2008 of provisional application Ser. No. 61/106,472 and
the benefit of the filing date of Feb. 17, 2009 of provisional
application Ser. No. 61/153,271; (xii) is a continuation-in-part of
U.S. patent application Ser. No. 12/840,978, filed Jul. 21, 2010;
and (xiii) is a continuation-in-part of U.S. patent application
Ser. No. 12/706,576 filed Feb. 16, 2010 which claims, under 35
U.S.C. .sctn.119(e)(1), the benefit of the filing date of Jan. 15,
2010 of provisional application Ser. No. 61/295,562; and, (xiv) is
a continuation-in-part of U.S. patent application Ser. No.
13/366,882 filed Feb. 6, 2012, which claims, under 35 U.S.C.
.sctn.119(e)(1), the benefit of the filing date of Feb. 7, 2011 of
provisional application Ser. No. 61/439,970, the entire disclosures
of each of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The present inventions relate to high power laser systems,
high power laser tools, and methods of using these systems and
tools for removing structures objects, and materials, and in
particular, structures, objects, and materials in difficult to
access locations and environments, such as offshore, underwater, or
in hazardous environments, such as nuclear and chemical facilities.
Thus, the present inventions relate to high power laser systems,
high power laser tools, and methods of using these systems and
tools for removing structures, objects, and materials located
offshore, on an offshore coastal shelf, on a continental shelf, in
coastal waters, above the surface of a body of water, below the
surface of a body of water, below and above the surface of a body
of water, on the bottom of a body of water, e.g., the seafloor,
below the bottom of a body of water, e.g., below the seafloor, and
combinations and variations of these. In particular, the present
inventions relate to the removal of offshore structures, such as:
platforms used for the exploration and production of hydrocarbons;
oil and gas wells; oil and gas fields; platforms used to support
windmills; structures used to support bridges, causeways or piers;
pipelines; and power cables.
[0003] As used herein, unless specified otherwise "offshore,"
"offshore activities" and "offshore drilling activities" and
similar such terms are used in their broadest sense and would
include drilling and other activities on, or in, any body of water,
whether fresh or salt water, whether manmade or naturally
occurring, such as for example rivers, lakes, canals, inland seas,
oceans, seas, bays and gulfs, such as the Gulf of Mexico. As used
herein, unless specified otherwise the term "offshore drilling rig"
is to be given its broadest possible meaning and would include
fixed platforms, tenders, platforms, barges, dynamically positioned
multiservice vessels, lift boats, jack-ups, floating platforms,
drill ships, dynamically positioned drill ships, semi-submersibles
and dynamically positioned semi-submersibles.
[0004] As used herein, unless specified otherwise the term "fixed
platform," would include any structure that has at least a portion
of its weight supported by the seafloor. Fixed platforms would
include structures such as: free-standing caissons, monopiles,
well-protector jackets, pylons, braced caissons, piled-jackets,
skirted piled-jackets, compliant towers, gravity structures,
gravity based structures, skirted gravity structures, concrete
gravity structures, concrete deep water structures and other
combinations and variations of these. Fixed platforms extend from
at or below the seafloor to and above the surface of the body of
water, e.g., sea level. Deck structures are positioned above the
surface of the body of water on top of vertical support members
that extend down into the water to the seafloor and into the
seabed. Fixed platforms may have a single vertical support, or
multiple vertical supports, or vertical diagonal supports, e.g.,
pylons, legs, braced caissons, etc., such as a three, four, or more
support members, which may be made from steel, such as large hollow
tubular structures, concrete, such as concrete reinforced with
metal such as rebar, and combinations and variations of these.
These vertical support members are joined together by horizontal,
diagonal and other support members. In a piled-jacket platform the
jacket is a derrick like structure having hollow essentially
vertical members near its bottom. Piles extend out from these
hollow bottom members into the seabed to anchor the platform to the
seabed.
[0005] The construction and configuration of fixed platforms can
vary greatly depending upon several factors, including the intended
use for the platform, load and weight requirements, seafloor
conditions and geology, location and sea conditions, such as
currents, storms, and wave heights. Various types of fixed
platforms can be used over a great range of depths from a few feet
to several thousands of feet. For example, they may be used in
water depths that are very shallow, i.e., less than 50 feet, a few
hundred feet, e.g., 100 to 300 feet, and a few thousand feet, e.g.,
up to about 3,000 feet or even greater depths may be obtained.
These structures can be extremely complex and heavy, having a total
assembled weight of more than 100,000 tons. They can extend many
feet into the seafloor, as deep as 100 feet or more below the
seafloor.
[0006] Examples of fixed platforms are provided in FIGS. 20 A-C.
Where a triangular-pile-jacket, a rectangular-pile-jacket, and a
gravity structure are illustrated, respectively. The conductors
2001 are shown within the structure of pile jacket platforms. To
the extent utilized in the gravity structure, the conductors would
be contained within the vertical support members 2002 of the
gravity structure, and thus, are not shown in FIG. 20C. The
conductors extend from the deck structures of the platform, 2005,a,
b, c above the surface 2006 of the body of water 2007, to and into
the seabed 2008. The conductors contain, e.g., hose, tubulars,
which are used for among other things recovery of hydrocarbons from
the formations below the seafloor. The size, weight, and
variability of fixed platforms, associated conductors, and other
structures and materials at, on, or within the seabed make their
removal difficult.
[0007] As used herein, unless specified otherwise the terms
"seafloor," "seabed" and similar terms are to be given their
broadest possible meaning and would include any surface of the
earth, including for example the mud line, that lies under, or is
at the bottom of, any body of water, whether fresh or salt water,
whether manmade or naturally occurring.
[0008] As used herein, unless specified otherwise the terms "well"
and "borehole" are to be given their broadest possible meaning and
include any hole that is bored or otherwise made into the earth's
surface, e.g., the seafloor or seabed, and would further include
exploratory, production, abandoned, reentered, reworked, and
injection wells.
[0009] As used herein the term "drill pipe" is to be given its
broadest possible meaning and includes all forms of pipe used for
drilling activities; and refers to a single section or piece of
pipe. As used herein the terms "stand of drill pipe," "drill pipe
stand," "stand of pipe," "stand" and similar type terms are to be
given their broadest possible meaning and include two, three or
four sections of drill pipe that have been connected, e.g., joined
together, typically by joints having threaded connections. As used
herein the terms "drill string," "string," "string of drill pipe,"
string of pipe" and similar type terms are to be given their
broadest definition and would include a stand or stands joined
together for the purpose of being employed in a borehole. Thus, a
drill string could include many stands and many hundreds of
sections of drill pipe.
[0010] As used herein the term "tubular" is to be given its
broadest possible meaning and includes conductor, drill pipe,
casing, riser, coiled tube, composite tube, vacuum insulated tube
("VIT"), production tubing, piles, jacket components, offshore
platform components, production liners, pipeline, and any similar
structures having at least one channel therein that are, or could
be used, in the drilling, production, refining, hydrocarbon,
hydroelectric, water processing, chemical and related industries.
As used herein the term "joint" is to be given its broadest
possible meaning and includes all types of devices, systems,
methods, structures and components used to connect tubulars
together, such as for example, threaded pipe joints and bolted
flanges. For drill pipe joints, the joint section typically has a
thicker wall than the rest of the drill pipe. As used herein the
thickness of the wall of a tubular is the thickness of the material
between the internal diameter of the tubular and the external
diameter of the tubular.
[0011] As used herein the term "pipeline" should be given its
broadest possible meaning, and includes any structure that contains
a channel having a length that is many orders of magnitude greater
than its cross-sectional area and which is for, or capable of,
transporting a material along at least a portion of the length of
the channel. Pipelines may be many miles long and may be many
hundreds of miles long or they may be shorter. Pipelines may be
located below the earth, above the earth, under water, within a
structure, or combinations of these and other locations. Pipelines
may be made from metal, steel, plastics, ceramics, composite
materials, or other materials and compositions know to the pipeline
arts and may have external and internal coatings, known to the
pipeline arts. In general, pipelines may have internal diameters
that range from about 2 to about 60 inches although larger and
smaller diameters may be utilized. In general natural gas pipelines
may have internal diameters ranging from about 2 to 60 inches and
oil pipelines have internal diameters ranging from about 4 to 48
inches. Pipelines may be used to transmit numerous types of
materials, in the form of a liquid, gas, fluidized solid, slurry or
combinations thereof. Thus, for example pipelines may carry
hydrocarbons; chemicals; oil; petroleum products; gasoline;
ethanol; biofuels; water; drinking water; irrigation water; cooling
water; water for hydroelectric power generation; water, or other
fluids for geothermal power generation; natural gas; paints;
slurries, such as mineral slurries, coal slurries, pulp slurries;
and ore slurries; gases, such as nitrogen and hydrogen; cosmetics;
pharmaceuticals; and food products, such as beer.
[0012] Pipelines may be, in part, characterized as gathering
pipelines, transportation pipelines and distribution pipelines,
although these characterizations may be blurred and may not cover
all potential types of pipelines. Gathering pipelines are a number
of smaller interconnected pipelines that form a network of
pipelines for bringing together a number of sources, such as for
example bringing together hydrocarbons being produced from a number
of wells. Transportation pipelines are what can be considered as a
traditional pipeline for moving products over longer distances for
example between two cities, two countries, and a production
location and a shipping, storage or distribution location. The
Alaskan oil pipeline is an example of a transportation pipeline.
Distribution pipelines can be small pipelines that are made up of
several interconnected pipelines and are used for the distribution
to, for example, an end user, of the material that is being
delivered by the pipeline, such as for example the feeder lines
used to provide natural gas to individual homes. Pipelines would
also include, for example, j-tubes that interconnect subsea
pipelines with producing structures, pipeline end manifolds (PLEM),
and similar sub-sea structures; and would also include flowlines
connecting to, for example, wellheads. As used herein, the term
pipeline includes all of these and other characterizations of
pipelines that are known to or used in the pipeline arts.
[0013] As used herein, unless specified otherwise "high power laser
energy" means a laser beam having at least about 1 kW (kilowatt) of
power. As used herein, unless specified otherwise "great distances"
means at least about 500 m (meter). As used herein the term
"substantial loss of power," "substantial power loss" and similar
such phrases, mean a loss of power of more than about 3.0 dB/km
(decibel/kilometer) for a selected wavelength. As used herein the
term "substantial power transmission" means at least about 50%
transmittance.
[0014] Discussion of Related Arts
[0015] Sub-Sea Drilling
[0016] Typically, and by way of general illustration, in drilling a
subsea well an initial borehole is made into the seabed and then
subsequent and smaller diameter boreholes are drilled to extend the
overall depth of the borehole. Thus, as the overall borehole gets
deeper its diameter becomes smaller; resulting in what can be
envisioned as a telescoping assembly of holes with the largest
diameter hole being at the top of the borehole closest to the
surface of the earth. As the borehole is being extended, in this
telescoping fashion, casing may be inserted into the borehole, and
also may be cemented in place. Smaller and smaller diameter casing
will be used as the depth of the borehole increases.
[0017] Thus, by way of example, the starting phases of a subsea
drill process may be explained in general as follows. In the case
of a floating rig, once the drilling rig is positioned on the
surface of the water over the area where drilling is to take place,
an initial borehole is made by drilling a 36'' hole in the earth to
a depth of about 200-300 ft. below the seafloor. A 30'' casing is
inserted into this initial borehole. This 30'' casing may also be
called a conductor. The 30'' conductor may or may not be cemented
into place. During this drilling operation a riser is generally not
used and the cuttings from the borehole, e.g., the earth and other
material removed from the borehole by the drilling activity are
returned to the seafloor. Next, a 26'' diameter borehole is drilled
within the 30'' casing, extending the depth of the borehole to
about 1,000-1,500 ft. This drilling operation may also be conducted
without using a riser. A 20'' casing is then inserted into the 30''
conductor and 26'' borehole. This 20'' casing is cemented into
place. The 20'' casing has a wellhead, or casing head, secured to
it. (In other operations an additional smaller diameter borehole
may be drilled, and a smaller diameter casing inserted into that
borehole with the wellhead being secured to that smaller diameter
casing.) The wellhead, or casing head, would be located at the
seafloor. A blowout preventer ("BOP") is then secured to a riser
and lowered by the riser to the sea floor; where the BOP is secured
to the wellhead, or casing head. From this point forward, in
general, all drilling activity in the borehole takes place through
the riser and the BOP.
[0018] In the case of a fixed platform rig, once the drilling rig
is positioned on the seafloor over the area where drilling is to
take place, an initial borehole is made by drilling a 36'' hole in
the earth to a depth of about 200-300 ft. below the seafloor. A
30'' casing is inserted into this initial borehole. This 30''
casing may also be called a conductor. The 30'' conductor may or
may not be cemented into place. During this drilling operation a
riser is generally not used and the cuttings from the borehole,
e.g., the earth and other material removed from the borehole by the
drilling activity, are returned to the seafloor. In the case of a
fixed platform, the conductor extends from below the seafloor to
above the surface of the water, and generally to the platform
decking. Next, a 26'' diameter borehole is drilled within the 30''
casing, extending the depth of the borehole to about 1,000-1,500
ft. This drilling operation is conducted within the conductor. A
20'' casing is then inserted into the 30'' conductor and 26''
borehole. This 20'' casing is cemented into place and extends from
below the seafloor to the above the surface of the sea. The 20''
casing has a wellhead, or casing head, secured to it. (In other
operations, an additional smaller diameter borehole may be drilled,
and a smaller diameter casing inserted into that borehole with the
wellhead being secured to that smaller diameter casing.) With a
fixed platform, the wellhead or casing head, is located above the
surface of the body of water and generally in the decking area of
the platform. A BOP is then secured to the wellhead or casing head.
From this point forward, in general, all drilling activity in the
borehole takes place through the BOP.
[0019] During completion of the well a production liner and within
the production liner a production pipe are inserted into the
borehole. These tubulars extend from deep within the borehole to a
structure referred to as a Christmas tree, which is secured to the
wellhead or casing head. (Other structures, in addition to,
including, or encompassed by a Christmas tree, such as a tree,
production tree, manifold and similar types of devices may be
secured to or associated with the wellhead, casing head or
conductor.) In sub-sea completions, the Christmas tree is located
on the sea floor. In completions using a fixed platform, the
Christmas tree is located above the surface of the body of water,
in the platforms deck, atop the conductor. During production,
hydrocarbons flow into and up the production pipe to the Christmas
tree and from the Christmas tree flow to collection points where
they are stored, processed, transferred and combinations of these.
Depending upon the particular well, a conductor may have many
concentric tubulars within it and may have multiple production
pipes. These concentric tubulars may or may not be on the same
axis. Further, these concentric tubulars may have the annulus
between them filled with cement. A single platform may have many
conductors and for example may have as many as 60 or more, which
extend from the deck to and into the seafloor.
[0020] The forgoing illustrative examples have been greatly
simplified. Many additional steps, procedures, tubulars and
equipment (including additional equipment, power lines and
pipelines on or below the seafloor) maybe utilized to proceed from
the initial exploratory drilling of a well to the actual production
of hydrocarbons from a field. At some point in time, a well or a
collection of wells, will no longer be economically producing
hydrocarbons. At which point in time the decision may be made to
plug and abandon the well, several wells, and to additionally
decommission the structures associated with such wells. As with the
steps to drill for and produce hydrocarbons, the steps for
plugging, abandoning and decommissioning are complex and
varied.
[0021] Prior Methodologies to Remove Subsea Structures
[0022] There are generally several methodologies that have been
used to remove structures from the seafloor. These methodologies
may general be categorized as: complex saws, such as diamond saws:
large mechanical cutters or shears; oxygen-arc or torch cutters;
abrasive water jets; and explosives. Additionally, there may be
other methodologies, including the use of divers and ROVs to
physically scrap, chip, cut or otherwise remove material. All of
these methodologies have health, safety, environmental, and
reliability drawbacks.
[0023] A key and critical factor for any methodology that is used
for the removal of subsea structures is that when subsea structures
are cut-up for lifting out of the sea, these cuts must be complete.
Thus, A. Culwell, Removal and Disposal of Deck and Jacket
Structures, p. 52 (contained in "The Process of Decommissioning and
Removing Offshore and Associated Onshore Oil and Gas Facilities",
1997) ("A. Culwell"), notes that: "[i]t is crucial to the safety of
the heavy lifts that these cuts be complete and reliable because
they could not be examined for verification." Culwell, at page 52,
further notes that "abrasive water jet methodology . . . does not
have guaranteed success and many cuts were repeated or completed
with divers working inside the caisson legs after [abrasive water
jet] cuts proved to be incomplete."
[0024] Diamond saws and mechanical cutters have similar reliability
failings. Diamond saws, as well as, abrasive water jets, are also
slow in making their cuts, and thus, can be time consuming, which
along with other factors, greatly adds to the overall removal
costs. Oxygen-arc or torch cutters are similarly slow, may require
divers, and thus, subject the divers to hazardous conditions, such
as being inside of a caisson. Additionally, these cutters will not
cut all types of material, for example concrete, which may require
for example a diver to chip the cement away.
[0025] Explosives, although reliable are dangerous to both humans
and marine life, and in particular, to marine mammals. The use of
explosives above the sea floor is being greatly restricted, and to
protect marine life, these restrictions may extend to activities
just below the sea floor, e.g., about 15 feet down or less. The
abrasives used in abrasive water jets also have environmental
concerns, although the study of this has only recently been
started. The abrasive material used may prove dangerous to marine
life and harmful to the environment.
[0026] High Power Laser Transmission
[0027] Prior to the recent breakthroughs of Foro Energy
co-inventors it was believed that the transmission of high power
laser energy over great distances without substantial loss of power
was unobtainable. Their breakthroughs in the transmission of high
power laser energy, in particular power levels greater than 5 kW,
are set forth, in part, in the novel and innovative teachings
contained in the following US Patent Application Publications
Publication No. 2010/0044106; Publication No. 2010/0044104;
Publication No. 2010/0044103; Publication No. 2010/0215326; and,
Publication No. 2012/0020631, the entire disclosure of each of
which is incorporated herein by reference.
SUMMARY
[0028] In the removal, repair, cleaning and decommissioning of
structures located in difficult to access, harsh or hazardous
environments, such as offshore structures and nuclear facilities,
it has long been desirable to have the ability to reliably and
safely cut or section these structures for removal and to do so in
a controlled and predetermined manner. The present invention, among
other things, solves this need by providing the articles of
manufacture, devices and processes taught herein.
[0029] Thus, there is provided a method of and system for removing
a section of a member from an offshore structure, the method and
system including: operably associating a high power laser system
with the offshore structure, the high power laser system including
a high power laser and a high power laser cutting tool; the high
power laser cutting tool defining a laser beam delivery path for
delivery of a high power laser beam along the beam path;
positioning the laser cutting tool adjacent a member of the
offshore structure, whereby the laser beam path extends from the
cutting tool to the member; propagating a high power laser beam
along the beam path and moving the beam path and laser beam thereby
cutting the member, whereby a section of the member is formed in a
predetermined manner; and, removing the section from the
structure.
[0030] Further, there are provided such laser methods and systems
that include methods and systems in which the member is located
below a surface of a body of water, the member is a tubular and the
cut is an inside-to-outside cut, the member is a tubular and the
cut is an outside-to-inside cut, at least a portion of the member
is located above the surface of a body of water, at least a portion
of the member is located below a sea floor, at least a portion of
the member is in the sea floor, the laser beam path is positioned
in the body of water, the laser beam path is positioned below a sea
floor, the laser beam propagated along the beam path is at least
about 5 kW, the laser beam propagated along the beam path is at
least about 10 kW, the laser beam propagated along the beam path is
at least about 15 kW, the high power laser system has a laser
cutting platform and positioning the laser cutting platform above a
surface of a body of water the laser cutting platform, including an
operably associated device for hoisting an operably associated
laser cutting device for cutting and, an operably associated device
for holding; wherein the operably associated laser cutting device
defines a second beam path; and, propagating a laser beam along the
second beam path, the laser beam propagated along the cutting tool
beam path is at least 5 kW and the laser beam propagated along the
second beam path is at least 5 kW.
[0031] Yet additionally, there are provided laser systems and cut
verification systems and verification methods in which the cut
verification is passive, the cut verification is real-time and
based at least in part on monitoring the laser beam, and the cut
verification is based at least in part on laser range finding.
[0032] Moreover there is provided an offshore method of cutting
material associated with an offshore structure including:
positioning a high power laser system over a body of water and
proximate to the location of the offshore structure, the high power
laser system including a high power laser and a high power laser
cutter assembly; the high power laser cutter assembly defining a
laser beam delivery path for delivery of a high power laser beam
along the beam path; propagating a high power laser beam along the
beam path, the laser beam having a power of at least 5 kW; and,
changing the relative position of the material to be sectioned and
the laser beam path in a predetermined laser beam delivery pattern,
whereby the laser beam cuts the material in a predetermined
cut.
[0033] Yet additionally, there are provided such laser methods
including a method in which the predetermined delivery pattern is a
continuous ring around the circumference of a tubular, the
predetermined cut is a pair of openings for affixing a lifting
device, the laser beam propagated along the beam path strikes a
platform jacket member, the laser beam propagated along the beam
path strikes a platform jacket member in a circular pattern, the
laser beam propagated along the beam path strikes a platform pylon
in a circular pattern, the predetermined pattern or manner has a
land area and a cut area, the laser beam is delivered in a
predetermined including a single pass pattern of beam delivery,
wherein the laser beam completely severs the material in a single
pass of the laser beam, the laser beam is delivered in a beam
pattern including a substantially vertical beam path, the laser
beam is delivered in a beam pattern including a substantially
horizontal beam path, the laser beam is delivered in a pattern
including a substantially vertical beam path and a substantially
horizontal beam path, the laser beam is delivered in a beam pattern
including a substantially axial beam path, the laser beam is
delivered in a beam pattern including a substantially radial beam
path, the laser beam is delivered in a pattern including a
substantially axial beam path and a substantially radial beam
path.
[0034] Yet further, there is provided a method of cutting material
associated with an offshore structure including: positioning a high
power laser system proximate to the offshore structure in a body of
water, the high power laser system including a high power laser
optically associated by means of an umbilical with a high power
laser cutter assembly; the high power laser cutter assembly
defining a laser beam delivery path for delivery of a high power
laser beam along the beam path; positioning the beam path below the
surface of the body of water; propagating a high power laser beam
along the beam path below the surface of the body of water; and,
changing the relative position of a member to be cut and the laser
beam path, whereby the laser beam strikes the member below the
surface of the body of water and thereby cuts the member below the
surface of the body of water.
[0035] Moreover, there are provided laser methods including methods
in which the laser beam is propagated along the beam path is
positioned below a seafloor of the body of water, the laser beam
path when the laser beam is propagated along the beam path is
positioned in a mudline of the body of water, the laser beam path
when the laser beam is propagated along the beam path is positioned
below a mudline of the body of water, the structure is an oil
platform, the structure is a jacket and pile structure, the
structure is a monopile structure, the structure is a pipeline, the
structure is a bridge support, the member has an inner steel
tubular, and an outer steel tubular, the inner steel tubular and
the outer steel tubular define an annulus, the annulus is at least
partially filled with air, the annulus is at least partially filled
with a solid material, the solid material is cement, the laser beam
propagated along the beam path strikes an inner tubular positioned
within an outer tubular and whereby upon completion of the cutting
the inner tubular is severed and the outer tubular is not cut by
the laser beam, and the laser beam propagated along the beam path
strikes an inner tubular positioned within an outer tubular and
whereby upon completion of the cutting the inner tubular is severed
and the outer tubular is severed.
[0036] Furthermore, there is provided a method of plugging and
abandoning a well using a high power laser system, the method
including: selecting a well, the well having tubulars contained
within the well and at least one tubular extending from a location
within the well below the surface of the earth to location above
the surface of the earth; determining the configuration of at least
some of the tubulars; formulating a plugging and abandonment plan
for the well based in part upon the configuration of at least some
of the tubulars; the plugging and abandonment plan including the
steps of: cutting a tubular at a predetermined location within the
well and removing the tubular above the cut from the well; placing
a plug within the well; cutting and removing all tubulars from the
well at least about three feet below the surface of the earth; and,
performing at least one of the planned cuts with a high power laser
beam. Moreover, such cuts may also include cuts in which a
plurality of the planned cuts are performed with a high power laser
beam, substantially all of the planned cuts are performed with a
high power laser beam, and the surface of the earth is a sea
floor.
[0037] Yet still further, there is provided a method of plugging
and abandoning a well using a high power laser system, the method
including: selecting a borehole in the surface of the earth forming
a well, the borehole having a tubular contained therein, the
tubular extending below the surface of the earth; placing a first
plug within the borehole; cutting the tubular at a location within
the borehole and removing at least a some of the cut tubular from
the borehole; placing a second plug within the borehole, the second
plug being located closer to the surface of the earth than the
first plug; delivering a high power laser beam along a beam path to
cut all tubulars within the borehole at a second location above the
second plug, wherein the delivery of the laser beam completely
severs all tubulars at the location within the borehole; and,
removing all of the severed tubulars from the borehole above the
second location, wherein the borehole above the second location is
free from tubulars. Yet further there are provided such laser
methods in which the second location to be cut is at least about 3
feet below the surface of the earth and the surface of the earth is
a sea floor, the second location is at least about 5 feet below the
surface of the earth and the surface of the earth is a sea floor,
the second location is at least about 10 feet below the surface of
the earth and the surface of the earth is a sea floor, the second
location is at least about 15 feet below the surface of the earth
and the surface of the earth is a sea floor.
[0038] Still furthermore, there is provided a method of removing a
conductor from a body of water using a high power laser system, the
method including: positioning a high power laser cutting tool
proximate a location on the conductor below a surface of the body
of water; directing a high power laser beam along a beam path from
the laser cutting tool to the first location, wherein the laser
beam severs the conductor at about the first location, thereby
creating a severed section of the conductor above the first
location; and raising the severed section of the conductor above
the surface of the body of water.
[0039] Moreover, there is provided a method of removing
contamination from an offshore structure to lessen the weight of
the structure, the method including: positioning a high power laser
system over a body of water and proximate to the location of the
offshore structure, the high power laser system including a high
power laser optically associated with a high power laser delivery
assembly; the high power laser delivery assembly defining a laser
beam delivery path for delivery of a high power laser beam along
the beam path; positioning the beam path between the delivery
assembly and a location of the structure; propagating a high power
laser beam along the beam path, the laser beam having a beam
property; scanning the high power laser beam from the location on
the structure to a second location on the structure at a rate,
whereby the beam property and scan rate are such that contamination
is removed from the structure without substantial damage to the
structure. Yet further such methods may include methods in which
the beam property is a power of the beam, the beam property is a
pulse rate of the beam, the beam is pulsed, and the beam property
is a duty cycle.
[0040] Additionally, there is provided a method of removing large
heavy offshore structures from a body of water, without the need
for heaving hoisting equipment, the method including: positioning a
high power laser system over a body of water and proximate to the
location of the offshore structure, the high power laser system
including a high power laser optically associated with a high power
laser delivery assembly; determining a laser cutting plan for
cutting the structure into sections of a predetermined size and
weight; laser cutting the structure below a surface of the body of
water into a predetermined section; and, removing the predetermined
section from the body of water. Such methods may also include
methods in which the majority of the predetermined sections are
less than about 500 tons, the majority of the predetermined
sections are less than about 200 tons, the majority of the
predetermined sections are less than about 100 tons, the majority
of the predetermined sections are less than about 50 tons, and
include a laser beam having a wavelength of greater than about 1000
nm to about 1550 nm.
[0041] Yet still additionally, there is provided a laser
decommissioning, plugging and abandoning vessel including: a
vessel; a high power laser having at least about 10 kW of power; a
means for high power laser cutting; and, a means for optically
associating the laser and the means for cutting. Such vessels may
also include at least a vessel in which the laser cutting means has
a means for positioning a laser beam path between the laser cutting
tool and a member to be cut for making an inside-to-outside cut,
the laser cutting tool has a means for positioning a laser beam
path between the laser cutting tool and a member to be cut for
making a outside-to-inside cut, the laser propagates a laser beam
having a wavelength of about 1060 nm to about 2100 nm, the laser
cutting means has a fluid laser jet nozzle, the laser cutting means
has a total internal reflection prism, the laser cutting means has
an anchoring means, a laser cutting head, and a means for extending
the laser cutting head from the anchoring means, a laser radar cut
verification means in association with the laser cutting means, a
passive cut verification means, a real-time cut verification means,
the laser cutting means has a means for passive cut verification,
the laser cutting means has a means for laser radar cut
verification, the vessel is a barge, the vessel is a ship.
[0042] Moreover, there is provided a mobile laser removal system,
capable of being placed on a vehicle, vessel, platform, or offshore
structure, the system including: a high power laser having at least
5 kW of power; and, a subsea high power laser cutting tool; and, an
umbilical for optically associating the high power laser with the
subsea high power laser cutting tool.
[0043] Yet further, there is provided an underwater laser cutting
tool, including: a laser tool body defining a longitudinal axis and
including a conveyance termination section and an anchoring
section; a stand-off distance setting device, whereby the laser
tool body axis may be positioned in a predetermined location
relative to an axis of a tubular to be cut; a motor section; a
laser cutting head section, including a laser beam exit; and a
laser optics defining an axis.
[0044] There are further provided such underwater laser cutting
tools in which the optics axis and the laser tool body axis are
coaxial, the predetermined stand off distance provides for the tool
body axis to be coaxial with the tubular axis, the predetermined
stand off distance provides for the optics axis to be coaxial with
the tubular axis, and the predetermined stand off distance provides
for the tool body axis and the optics axis to be coaxial with the
tubular axis.
[0045] Moreover, there are provided such underwater laser cutting
tools including at least a packer, a passage for handling returns,
a gas laser jet nozzle, an extending section between the laser
cutting head section and the anchoring section, whereby the laser
cutting head section is capable of being advance through mud,
without the need for dredging.
[0046] Still further, there is provided an offshore laser services
system, capable of providing offshore laser decommissioning,
plugging, abandonment, cleaning, or cutting services, the system
including a remote operated vehicle; a laser module; an umbilical;
and, a laser cutting tool; which in this manner the system is
capable of laser cutting offshore materials selected from the group
consisting of mooring chains, subsea pipelines, jacket structures,
piles, conductors, tubulars, and control umbilicals. There is
further provided such system including a second laser cutting tool,
including a means for fixedly associating the laser cutting tool
with a structure to be laser cut.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] FIGS. 1A to 1F are illustrations of an embodiment of a laser
decommissioning, plugging and abandonment process and system in
accordance with the present invention.
[0048] FIG. 2 is a schematic of an embodiment of a laser cutting
tool in accordance with the present invention.
[0049] FIG. 3 is a schematic of an embodiment of a laser cutting
tool in accordance with the present invention.
[0050] FIG. 4 is a schematic of an embodiment of a laser cutting
tool in accordance with the present invention.
[0051] FIG. 5A is a schematic of an embodiment of a laser cutting
system in accordance with the present invention.
[0052] FIG. 5B is a schematic of an embodiment of a laser cutting
system in accordance with the present invention.
[0053] FIG. 6A is a schematic of an embodiment of a laser cutting
system in accordance with the present invention.
[0054] FIG. 6B is a schematic of an embodiment of a laser cutting
system in accordance with the present invention.
[0055] FIG. 7 is a schematic of an embodiment of a laser cutting
tool in accordance with the present invention.
[0056] FIG. 8 is a schematic of an embodiment of a laser removal
system and method in accordance with the present invention.
[0057] FIG. 9 is a perspective view of an embodiment of a laser
cutting station in accordance with the present invention.
[0058] FIG. 10 is a schematic of an embodiment of a laser system in
accordance with the present invention.
[0059] FIG. 11 is a cross sectional view of a laser cutting tool
and process in accordance with the present invention.
[0060] FIG. 12 is a schematic view of an embodiment of a laser
cutting head in accordance with the present invention.
[0061] FIG. 13 is a perspective view of a laser nozzle assembly in
accordance with the present invention.
[0062] FIG. 14 is a perspective view of a laser nozzle assembly in
accordance with the present invention.
[0063] FIG. 15A is a cross sectional view of a laser nozzle
assembly in accordance with the present invention.
[0064] FIG. 15B is a cross sectional prospective view of a portion
of the laser nozzle assembly of FIG. 15A.
[0065] FIG. 16A is a perspective view of a laser nozzle assembly in
accordance with the present invention.
[0066] FIG. 16B is a cross sectional view of portions of the nozzle
assembly of FIG. 16A.
[0067] FIG. 16C is a cross sectional view of the nozzle assembly of
FIG. 16C.
[0068] FIG. 17 is a cross sectional view of a laser cutting head in
accordance with the present invention.
[0069] FIG. 17A is a cross sectional view of the embodiment of FIG.
17 taken along line A-A of FIG. 17.
[0070] FIG. 17B is a cross sectional view of the embodiment of FIG.
17 taken along line B-B of FIG. 17.
[0071] FIG. 17C is a cross sectional view of a section of the
embodiment of FIG. 17.
[0072] FIG. 17D is a cutaway cross sectional perspective view of
the embodiment of FIG. 17.
[0073] FIG. 18 is a schematic view of a laser jet assembly in
accordance with the present invention.
[0074] FIG. 19 is a schematic view of a laser cutting head in
accordance with the present invention.
[0075] FIG. 19A is a cross sectional view of the embodiment of FIG.
19 taken along line A-A of FIG. 19.
[0076] FIGS. 20A to 20C are illustrations of embodiments of
offshore structures.
[0077] FIG. 21 is a schematic of an embodiment of a monopile
structure and associated laser decommissioning system in accordance
with the present invention.
[0078] FIG. 22 is a schematic of an embodiment of a tripod
structure and associated laser decommissioning system in accordance
with the present invention.
[0079] FIG. 23 is a schematic of an embodiment of a gravity
structure and associated laser decommissioning system in accordance
with the present invention.
[0080] FIG. 24 is a schematic of an embodiment of a laser tool in
accordance with the present invention.
[0081] FIG. 25 is a schematic of an embodiment of a laser tool in
accordance with the present invention.
[0082] FIG. 26 is a schematic of an embodiment of a laser tool in
accordance with the present invention.
[0083] FIG. 27A is a cross sectional view of an embodiment of a
laser head in accordance with the present invention.
[0084] FIG. 27B is a cross sectional view of a section of the laser
head of the embodiment of FIG. 27A.
[0085] FIG. 27C is a perspective view of a section of the laser
head of the embodiment of FIG. 27A.
[0086] FIG. 28 is a perspective view of an embodiment of a laser
cutting tool in accordance with the present invention.
[0087] FIG. 29 is a perspective view of an embodiment of a laser
cutting tool in accordance with the present invention.
[0088] FIG. 30 is a cross sectional view of an embodiment of a
laser cutting tool in accordance with the present invention.
[0089] FIG. 31 is a schematic view of an embodiment of a laser
cutting tool in accordance with the present invention.
[0090] FIG. 32 is a perspective view of an embodiment of a laser
cutting tool in accordance with the present invention.
[0091] FIG. 33 is a schematic view of an embodiment of a laser
cutting tool in accordance with the present invention.
[0092] FIG. 34 is a cross sectional view of a laser cutting tool in
accordance with the present invention.
[0093] FIG. 34A is a perspective view of the prism assembly of the
laser cutting tool of the embodiment of FIG. 34.
[0094] FIG. 34B is a perspective view of the motor section of the
laser cutting tool of the embodiment of FIG. 34.
[0095] FIG. 34C is a perspective and schematic view of an
embodiment of an integrated umbilical of the embodiment of FIG.
34.
[0096] FIG. 35A to 35M are cross sectional schematic views of
material configurations cut in the embodiments of Example 21 in
accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0097] In general, the present inventions relate to the removal of
objects, structures, and materials in difficult to access,
hazardous or harsh environments using high power laser energy to
cut or section items into sizes that are removable, or more easily
removed. The ability to quickly and reliably cut such items into
predetermined sizes provides many advantages, including
environmental and safety, as well as, providing cost benefits.
Although not limited to the plugging, abandonment and
decommissioning of offshore oil wells and platforms, the present
inventions provide particular advantages, and solve long-standing
needs, in such applications.
[0098] In about 1946 the first exploratory oil well was drilled in
the Gulf of Mexico. From that point forward, through the present
time, there has been considerable activity to explore, develop and
produce hydrocarbons from offshore fields in the Gulf of Mexico and
in other offshore areas of the world. These efforts have resulted
in many thousands of fixed platforms being constructed over the
last fifty years. A large number of these platforms are reaching
the end of their useful lives, and more will be doing so in the
future. Although some of these platforms are left to form reefs, in
general they are required to be removed, for various environmental,
navigation, and aesthetic reasons, among others. Thus, the present
inventions find significant use and provide significant benefits to
the plugging, abandonment and decommissioning of offshore
hydrocarbon producing platforms and facilities.
[0099] Turning to FIGS. 1A and 1B, there is shown a fixed platform
that has gone through an embodiment of the laser plugging and
abandonment methods of the present invention for the platform and
its associated wells. In FIGS. 1A-B, there is provided a fixed
platform 1001. The fixed platform has a jacket, or jacket
structure, 1002, which has four vertical support members, or legs,
1003. (Only three of the four legs 1003 are shown in the view of
FIG. 1.) The legs 1003 are connected together by horizontal
members, e.g., 1004 and tie members, e.g., 1005. It being
understood by those of skill in the offshore platform arts that
jacket structures may be substantially more complex, larger, and
have more, less, or different legs, horizontal members and tie
members.
[0100] The jacket 1002 extends from the seafloor 1010 through the
body of water, or water column, 1011 and extends above the surface
1012 of the body of water 1011. The jacket supports a deck
structure 1006 above the surface 1012 of the body of water 1011.
The deck structure has a lower deck 1007 and an upper deck 1008. It
being understood by those of skill in the offshore platform arts
that the deck structures may be more or less complex and that more
or less decks may be present. The upper deck may have a derrick
1009 that has associated with it, for example, a drawworks, top
drive, iron rough neck and rig floor. A mast or other hoisting and
supporting structure may be present, or no such structure may be
present. The upper deck has a high power laser module 1015.
[0101] The high power laser module 1015 may have a high power laser
room, spool, which may be hydraulically operated, electrically
operated, or other means of providing mechanical motion and
rotation, and control system, for example of the types taught and
disclosed the following U.S. patent application Ser. No.
13/403,741; Ser. No. 13/403,723; Ser. No. 13/403,692; Ser. No.
13/347,445; and Ser. No. 13/210,581, the entire disclosures of each
of which are incorporated herein by reference.
[0102] The laser module 1015 may be a permanent installation on the
platform, having been used for drilling work over and completion
activities during the life of the platform. It may also be a mobile
unit that was placed on the deck 1008 for another purpose, such as
the removal of equipment and activities such as plugging
abandonment and decommissioning. The laser module, or components
thereof, may also be located on a separate vessel or structure,
such as a jack-up rig, barge, lift boat, dynamically positioned
vessel, or work boat, positioned near the platform.
[0103] The lower end of the jacket 1002 rests on, or in, the
seafloor 1010. The jacket 1002 is secured to the seafloor 1010 by
piles 1013, 1014. The piles are located within hollow portions, or
cavities, of the legs 1003. Although not seen in FIG. 1, each leg
has a pile associated with it. These piles may be, and generally
are, hollow tubulars that for example, may range in diameter from
about 20'' to about 214'' and have wall thickness ranging from
about 1/4'' to about 3''. There are many and varied manners of
associating piles with legs, of securing piles into the sea floor,
and of securing or otherwise fixing a pile-jacket type platform in
place, which are known by those of skill in the offshore platform
arts. The piles extend into the seafloor many feet, (in the range
of hundreds of feet) and typically extend much deeper than 20 feet,
below the seafloor. The piles may be filled with, or otherwise
contain, mud, sand earth and other materials. Although shown as
ending well below the surface 1012 of the water 1011, the piles may
extend up to and above the surface 1012.
[0104] The platform 1001 has conductors 1016, 1017, 1018 that
extend from the deck structure 1006 into the body of water 1011 to,
and into, the seafloor 1010. The conductors 1016, 1017, 1018 extend
through a frame, guide, or template 1019 that is placed on the
seafloor 1010. Each conductor would be associated with at least one
well, or borehole. Although not shown in FIGS. 1A-B, the conductors
typically pass through several sleeves or stabilizing devices as
they extend through decks and the jacket, as they pass into and
through a body of water. Although, only three conductors are shown
in the embodiment of FIGS. 1A-B, there may be from none, to 1, to
10, to 20, to 50, or more conductors associated with a single fixed
platform. Typically the conductors extend about 100 to 300 feet
into the earth below the seafloor. The conductors house, or
contain, other tubulars, such as casing, production liner and
production tubing. These other tubulars extend deep into the earth
potentially many thousands of feet deeper than the conductor. Some
of the annular spaces formed by the conductor and the tubulars
within it, may be filled with concrete, or other material. The
material may be located in the area that is at or near the
seafloor, and would extend down from the seafloor to more than 5,
more than 15, more than 20 feet below the seafloor, and potentially
hundreds, if not thousands, of feet below the seafloor.
[0105] Once it has been determined that a well is not going to be
used, the well will be plugged, and if there is no intention to
return to the well, abandoned. By way of example, a laser plugging
and abandonment procedure may generally involve some or all, of the
following activities and equipment, as well as other and additional
activities and equipment. Further laser plugging and abandonment
procedures and activities would include, by way of example, the use
of high power laser tools, systems, cutters and cleaners to perform
any and all of the type of activities that are set forth in BOEMRE
30 CFR 250, subpart Q, and including by way of example, activities
such as permanent abandonment, temporary abandonment, plug back to
sidetrack, bypass, site clearance and combinations and variations
of these. Such activities would further include, without limitation
the cutting, removal and/or modification of any structures (below
or above the surface of the earth and/or the sea floor) for the
purpose of temporarily or permanently ceasing and/or idling
activities. Examples of high power laser tools, systems, cutters
and cleaners that may be utilized for, or in, laser plugging and
abandonment procedures and activities for example are disclosed and
taught in the following U.S. patent applications and U.S. Patent
Application Publications: Ser. No. 13/403,741; Ser. No. 13/403,723;
Ser. No. 13/403,692; Ser. No. 13/347,445; Ser. No. 13/210,581; Ser.
No. 13/211,720; Ser. No. 13/366,882; Publication No. 2012/0020631;
Publication No. US 2010/0215326; US 2010/0044106; and, Publication
No. US 2010/0044103, the entire disclosures of each of which are
incorporated herein by reference. Laser plugging and abandonment
activities would also include: new activities that were unable to
be performed prior to the development of high power laser systems,
equipment and procedures taught and disclosed in the foregoing
patent applications and publications; existing procedures that
prior to the development of the high power laser systems, equipment
and procedures taught and disclosed in the foregoing patent
applications would have been unable to be performed in an
economically, safely and/or environmentally viable manner; and
combinations and variations of these.
[0106] After the valves on the wellhead and tree have been checked
to ensure proper operability, an inspection unit, such as a
wireline unit, slick line/electric line unit, slick line unit, or
similar type of unit, may be used to check, inspect and measure,
the borehole depth, gauge the internal diameter of the tubulars in
the borehole and determine other needed information about the
borehole. To the extent that there are any tools, valves, or other
downhole equipment, that are required or desirable to be removed,
but which are stuck downhole, the unit may be used to lower a laser
cutting tool and laser tool umbilical (or the umbilical may be used
without the need for a separate or additional line, e.g., a
wireline, depending upon the umbilical and laser module), to the
location of the stuck downhole equipment. The laser tool will
deliver a high power laser beam to the stuck downhole equipment,
cutting the equipment to sufficiently free it for recovery, by the
laser tool or the line, completely melting or vaporizing the stuck
equipment, and thus, eliminating it as an obstruction, or
combinations and variations of these. The well is then pressure
tested and any fluid communication between tubular annular spaces
is evaluated.
[0107] The laser module and laser cutting tool, or tools, may then
be used in conjunction with the platforms existing hoisting
equipment, e.g., the derrick 1009, and cementing, circulating and
pumping equipment, to plug and abandon the well. If such equipment
is not present on the platform, or for some other reason, other
hoisting, circulating or pumping equipment may be used, as needed,
in conjunction with, for example, a coil tubing rig having a laser
unit (e.g., the laser coil tubing system described in U.S. patent
application Ser. No. 61/446,312 and Ser. No. 13/403,741), or a
laser work over and completion unit (e.g., the mobile laser unit
described in U.S. patent application Ser. No. 61/446,312 and Ser.
No. 13/403,741) may be used. Additionally, a rig-less abandonment
and decommissioning system may have a laser removal system of the
present invention integrated into, or located on it. The laser
removal system may be configured to have a very small foot print,
and thus, take up only a small amount of deck space. The laser
removal system may substantially enhance, or expand, the
capabilities of the rig-less abandonment and decommissioning system
by enabling it to perform decommissioning projects that it
otherwise could not without the laser system's ability to cut and
section materials.
[0108] In general, and by way of example, plugging and abandonment
activities may involve the following activities, among others. A
cement plug is placed at the deepest perforation zone and extends
above that zone a predetermined distance, for example about 100
feet. After the plug has been placed and tested, the laser tool is
lowered into the well and the production tubing and liner, if
present, are cut above the plug and pulled. If there are other
production zones, whether perforated or not, cement plugs may also
be installed at those locations.
[0109] As the production tubing is pulled, it may be cut into
segments by a laser cutting device, or it may have been removed
before the decommissioning project began, and if jointed, its
segments may be unscrewed by pipe handling equipment and laid down.
The laser cutting device may be positioned on the rig floor, in
which instance the pipe handling equipment associated with the rig
floor can be used to raise and hold the tubing, while the laser
cutting device cuts it, remove the upper section of the cut tubing,
hold the lower section from falling, and then pull the lower
section of tubing into position for the next laser cut. In general,
for this type of pulling and cutting operation the laser cutting
tool may be located above a clamping device to hold the pipe and
below a hoisting device, such as a crane, top drive and drawworks,
to lift the pipe. The laser cutting device may be movably
positioned on the rig floor, for example in the manner in which an
iron rough neck is positioned.
[0110] A second, or intermediate, cement plug is installed a
location above the first plug and in the general area of a shoe of
an intermediate and surface casing. Additional intermediate plugs
may also be installed. During the installation of these cement
plugs, or other cement plugs or activities, to the extent that
circulation is needed to be established, or the annulus between
tubulars is required to be filled with cement, the laser tool may
be used to cut windows or perforations, at predetermined intervals
and to predetermined radial depths to establish circulation or
provide the ability to selectively fill an annulus with cement. It
being understood that these various steps and procedures generally
will be based at least in part on the well casing program.
[0111] Thus, for example, the laser tool may cut an opening through
an 113/4 inch casing, at a depth of 10,000 feet, and expose the
annulus between the 113/4 inch casing and a 135/8 inch casing. The
laser tool may then cut a second opening at a depth of 10,300 feet
exposing the same annulus. This ability to selectively open
tubulars and expose various annular spaces in a predetermined and
controlled manner may find application in various cleaning,
circulating, plugging and other activities required to safely and
properly plug and abandoned a well. This ability may also provide
benefits to meet future cleaning and plugging regulations or safety
requirements. For example, the ability to selectively expose
annular space, using the laser tool, and then fill it with cement
provides the ability to insure that no open annular space that
extends to the sea floor is left open to the borehole. The ability
to selectively expose annular space additionally provides the
ability to open or cut windows and perforations in a single piece
of casing or multiple pieces of casing at precise sizes and
shapes.
[0112] In general, any remaining uncemented casing strings, that
are located above the top most intermediate plug, may be cut by the
laser tool (using internal, external and combinations of both,
cuts) and then pulled from the well. (These strings may be
segmented by a laser cutting device, at the rig floor as they are
being pulled). A top cement plug starting at a fixed depth below
the sea floor (e.g., 50 to 100 feet) and extending down into the
borehole (e.g., an additional 200-300 feet) is then placed in the
well. In being recognized that the cement plug may be added
(filled) by flowing from the lower position up, or the upper end
position down.
[0113] The conductor, and any casings or tubulars, or other
materials, that may be remaining in the borehole, are cut at a
predetermined depth below the seafloor (e.g., from 5 to 20 feet,
and preferably 15 feet) by the laser cutting tool. Once cut, the
conductor, e.g., 1018, and any internal tubulars, are pulled from
the seafloor 1010 and hoisted out of the body of water 1011, where
they may be cut into smaller segments by a laser cutting device at
the rig floor, vessel deck, work platform, or an off-shore laser
processing facility. Additionally, biological material, or other
surface contamination or debris that may reduce the value of any
scrap, or be undesirable for other reasons, may be removed by the
laser system before cutting and removal, after cutting and removal
or during those steps at the various locations that are provided in
this specification for performing laser operations. Holes may be
cut in the conductor (and its internal cemented tubulars) by a
laser tool, large pins may then be inserted into these holes and
the pins used as a lifting and attachment assembly for attachment
to a hoist for pulling the conductor from the seafloor and out of
the body of water. As the conductor is segmented on the surface
additional hole and pin arrangements may be needed.
[0114] This process may then be repeated, or carried out in
parallel, with other wells that are to be plugged and abandoned.
Thus, as seen in FIG. 1B, using a laser plugging and abandonment
process, the conductors 1016, 1017, 1018 (and all internal
tubulars) have been cut about 15 feet below the seafloor, removed,
segmented and cleared from the platform site. In this example only
three conductors are shown, it being understood that there could be
50 or more conductors associated with a single platform and that
some, most or all of them may be removed and their associated wells
plugged and abandoned using laser plugging and abandonment
procedures. The laser cutting tool may cut at any depth below the
sea floor, and may cut any predetermined number of tubulars that
are concentric, eccentric, irregular shape from for example damage,
and combinations and variations of these. The depth of the cut will
be determined among other things by the regulations governing the
decommissioning project, the seafloor conditions, and the lifting
capacity of the hoisting equipment.
[0115] It is contemplated that internal, external and combinations
of both types of cuts be made on multi-tubular configurations,
e.g., one tubular located within the other. The tubulars in these
multi-tubular configurations may be concentric, eccentric,
concentrically touching, eccentrically touching at an area, have
grout or cement partially or completely between them, have mud,
water, or other materials partially or completely between them, and
combinations and variations of these.
[0116] Additionally, the laser systems provide an advantage in
crowded and tightly spaced conductor configurations, in that the
precision and control of the laser cutting process permits the
removal, or repair, of a single conductor, without damaging or
effecting the adjacent conductors.
[0117] The forgoing example of high power laser plugging and
abandonment activities is meant for illustration purposes only and
is not limiting, as to either the sequence or general types of
activities. Those of skill in the plugging and abandonment arts,
will recognize that there are many more and varied steps that may
occur and which may occur in different sequences during a plugging
and abandonment process. For example, the borehole between cement
plugs may be filled with appropriately weighted fluids or drilling
muds. Many of these other activities, as well as, the cutting,
segmenting, and plugging activities of the forgoing example, are
dictated by the particular and unique casing and cement profile of
each well, seafloor conditions, regulations, and how the various
tubulars have aged, degraded, or changed over the life of the well,
which could be 10, 20, or more years old.
[0118] The high power laser systems, methods, down hole tools and
cutting devices, provide improved abilities to quickly, safely and
cost effectively address such varied and changing cutting,
cleaning, and plugging requirements that may arise during the
plugging and abandonment of a well. These high power laser systems,
methods, down hole tools and cutting devices, provide improved
reliability, safety and flexibility over existing methodologies
such as explosives, abrasive water jets, milling techniques or
diamond band saws, in the laser's systems ability to meet and
address the various cutting conditions and requirements that may
arise during a plugging and abandonment project. In particular, and
by way of example, unlike these existing methodologies, high power
laser systems and processes, will not be harmful to marine life,
and they will ensure a complete and rapid cut through all types of
material. Unlike an explosive charge, which sound and shock waves,
may travel many miles, the laser beam for specific wavelengths,
even a very high power beam of 20 kW or more, has a very short
distance, e.g., only a few feet, through which it can travel
unaided through open water. Unlike abrasive water jets, which need
abrasives that may be left on the sea floor, or dispersed in the
water, the laser beam, even a very high power beam of 20 kW or
more, is still only light; and uses no abrasives and needs no
particles to cut with or that may be left on the sea floor or
dispersed in the water.
[0119] If the hydrocarbon field has reached the end of its useful
life, if the platform itself has reached the end of its useful
life, or if the platform has been irreparably damaged by, for
example a storm, then a laser decommissioning system may be
utilized to remove, e.g., decommission the platform. FIGS. 1C to 1F
provide snap shot illustrations of an embodiment of a method for
the laser removal of a fixed offshore platform that has already had
its wells plugged and abandoned. Thus, the jacket-pile platform
1001, in which all wells have been plugged and abandoned, is shown
in FIG. 1C with a laser decommissioning system 1050 being on
station.
[0120] The laser decommissioning system 1050, in the embodiment of
FIGS. 1C to 1F, has a vessel 1051, which in this embodiment may be
a barge, with a heavy lifting crane 1052, having for example
multiple hoists, with a main hoist having a lifting capacity of at
least about 100 tons, from about 100 tons to about 500 tons, and
greater than about 500 tons. The laser decommissioning system 1050,
however, by providing greater flexibility in the positioning of
cuts and in the speed of cutting, provides the ability to use a
substantially smaller crane than would be needed if existing
decommissioning methodologies were to be employed. The crane 1052,
has a boom 1054 that preferably has sufficient reach to assist in
the handling and movement of tubulars, structural components and
other material, as they are being cut, segmented or otherwise
processed in the laser cutting shop 1053. The laser decommissioning
system also has a high power laser module 1055, which may, for
example, have a high power laser room, spool, which may be
hydraulically operated, electrically operated, or other means of
providing mechanical motion and rotation, and control system. The
laser module 1055 may be a mobile laser unit or system or a laser
work over and completion unit or system, for example, of the types
taught and disclosed the following U.S. patent application Ser. No.
13/403,741; Ser. No. 13/403,723; Ser. No. 13/403,692; Ser. No.
13/347,445; and Ser. No. 13/210,581, the entire disclosures of each
of which are incorporated herein by reference, and variations and
combinations of those units and systems.
[0121] The laser module 1055 may be a permanent installation on the
decommissioning vessel, or it may be the module 1015, which had
been used on the platform 1001, and which is then relocated to the
vessel 1051. The laser module 1055, the laser cutting shop 1053, or
components thereof, may also be located on a separate vessel or
structure, such as a jack-up rig, barge or work boat, positioned
near the platform and a crane vessel or a hauling vessel (for
transporting the segmented platform sections, pulled tubulars and
other removed materials away from the site). Thus, the laser
decommissioning system may have a single structure (floating or
fixed) or many have multiple structures (floating or fixed) that
function together in the removal of the platform or other offshore
structure. The ability to transmit high power laser beams using
high power laser cables provides the ability to have many varied
configurations of vessels, structures, laser tools and laser
modules to customize or tailor a laser decommissioning system to
the particular requirements of a decommissioning project.
[0122] Turning to FIG. 1C, the upper deck 1008 of platform 1001 has
been removed, exposing the interior of the vertical members 1003 of
the jacket 1002. A laser cutting tool is then lowered down the
length of a vertical member 1003, a predetermined distance, to
sever a vertical member. This process is repeated for each of the
four vertical members. The predetermined distance is based upon
one, some, or all of several factors, including for example, the
configuration of the jacket, the hoisting capacity of the crane,
the holding capacity (both weight and deck space) of any transport
vessel, the dimensions of the section to be lifted, and the weight
of the section to be lifted.
[0123] In this manner the jacket is segmented into a section 1056
that is disconnected from the jacket. (It being recognized that any
horizontal members 1004, tie members 1005, or other structures that
could hold the section 1056 to the rest of the platform 1001 should
also be cut.) Crane 1052 may hold the section, during the cutting
of the vertical members, or other hoisting or positioning devices
may support it. Thus, the laser cutter cuts all vertical members
1003 of the platform 1001 completely through and creates section
1056 of the jacket 1002 for removal. The laser cutter's ability to
repeatedly and reliably provide a complete cut, and preferably with
only a single pass of the laser, provides a significant benefit in
assuring the reliability of the process. After all vertical and any
other connecting or tie members have been cut, the laser tool is
repositioned to an appropriate location, to avoid interference
with, or being damaged by, the lifting of the section 1056 out of
the body of water 1011.
[0124] Turning to FIG. 1D, the section 1056 has been hoisted out of
the body of water 1011, positioned on the work area, e.g., the
deck, of the barge 1051. The section 1056 has been cut, preferably
by a laser cutter, into two sections 1056a, 1056b. FIG. 1D further
shows a tubular member 1057 being feed into the laser shop 1053 for
sectioning.
[0125] The laser cuts to the vertical members of the jacket may be
made from the inside of the vertical members to the outside, or
from the outside of the vertical member to the inside. In the
inside-to-outside cut, the laser beam follows a laser beam path
starting from inside the vertical member, to the member's inner
surface, through the member, and toward the body of water or
seabed. For the outside-to-inside cut, the laser beam follows a
laser beam path starting from the outside of the vertical member,
i.e., in the laser tool, going toward the outer surface of the
vertical member, through the vertical member, and into its
interior. For the inside-to-outside cut the laser cutting tool will
be positioned inside of the vertical member, below the seafloor, in
the water column, above the body of water and combinations and
variations of these. For the outside to inside cut, the laser
cutting tool will be positioned adjacent to the outer surface of
the vertical member. In creating a section 1056 for removal from
the body of water 1011, only inside-out cuts, only outside-in cuts,
and combinations of these cuts may be used. Thus, for example,
because of wave action in the area of the intended cuts, all cuts
may be performed using the inside-outside beam path. Multiple laser
cutting tools may be used, laser cutting tools having multiple
laser cutting heads may be used, laser cutting tools or heads
having multiple laser beam delivery paths may be used, and
combinations of these. The sequence of the laser cuts to the
vertical members preferably should be predetermined. They may be
done consecutively, simultaneously, and in combinations and various
of these timing sequences, e.g., three vertical members may be cut
at the same time, followed by the cutting of a fourth, fifth and
sixth member cut one after the other.
[0126] While it is preferable to have the cuts of the vertical
members be clean and complete, and be made with just one pass of
the laser, the precision and control of the laser, laser cutting
tools, and laser delivery heads, provides the ability to obtain
types of predetermined cuts. These complete laser cuts provide the
ability to assure and to precisely determine and know the lifting
requirements for, and the structural properties of the section
being removed, as well as any remaining portions of the structure.
Such predetermined cuts may have benefits for particular lifting
and removal scenarios, and may create the opportunity for such
scenarios that were desirable or cost effective, but which could
not be obtained with existing removal methodologies. For example,
the vertical member may be cut in a manner that leaves
predetermined "land" section remaining. This could be envisioned as
a perforation with cuts (removed) areas and lands (areas with
material remaining). There may be a single cut and a single land
area, multiple cuts and lands and the land areas may make
collectively or individually, at least about 5%, at least about
10%, at least about 20%, at least about 50% of the circumference or
exterior area of the vertical member. The land areas could provide
added safety and stability as the vertical members are being cut.
The size and locations of the lands would be known and
predetermined, thus their load bearing capabilities and strength
would be determinable. Thus, for example, once all the perforation
cuts have been made, the heavy lifting crane may be attached to the
jacket section to be removed, a predetermined lifting force applied
by the crane to the section, and the lands cut freeing the section
for removal. The lands may also be configured to be a predetermined
size and strength that the crane is used to mechanically break them
as the section is lifted away from the remaining portion of the
jacket. This ability to provide predetermined cutting patterns or
cuts, provides many new and beneficial opportunities for the use of
the laser cutting system in the removal of offshore structures and
other structures.
[0127] The lands of a laser perforation cut, are distinguishable
and quite different from the missed cuts that occur with abrasive
water jet cutters. The location, size, consistency, and frequency
of the abrasive water jet cutter's missed cuts are not known,
planned or predetermined. As such, the abrasive water jet's missed
cuts are a significant problem, detriment and safety concern. On
the other hand, the laser perforated cuts, or other predetermined
custom laser cutting profiles, that may be obtained by the laser
removal system of the present inventions, are precise and
predetermined. In this manner, the laser perforation, or other
predetermined, cuts may enhance safety and provide the ability to
precisely know where the cuts and lands are located, to know and
predetermine the structural properties and dynamics of the member
that is being cut, and thus, to generally know and predetermine the
overall structural properties and dynamics of the offshore
structure being removed.
[0128] The ability to make precise and predetermined cuts that
structurally weaken support members, the platform, the jacket, or
an offshore structure, in a predetermined manner, provide the
ability for new and innovative ways to rig, handle and remove
offshore structure. For example, the structure may be cut in a
predetermined manner that enables it to be toppled and pulled using
a winching and flotation mechanism, and thus in essence be cut,
tipped and drag onto a vessel for further cutting and sectioning.
Persons of skill in the offshore platform and decommissioning arts,
upon reviewing the teachings of this specification, may develop
many new and innovative techniques for rigging, handling and
removing structures based upon the capabilities of the present
laser cutting tools, devices, systems and methods, which techniques
will fall within the scope of protection for the present
inventions.
[0129] Turning to FIG. 1E, a further section 1060 of the jacket
1002 has been cut by a laser cutter and hoisted to the work area of
the vessel 1051. Section 1060 may then be further cutup by laser
tools, the laser shop 1053 and combinations of these, to be reduced
to sections of an appropriate weight and size for disposal or
recycle, as scrap metal.
[0130] The laser cutting shop 1053, and high power laser cutters,
provides the ability to quickly and efficiently reduce larger
pieces of material, such as conductors or vertical members of a
jacket, into much smaller and more readily manageable components.
The high power laser further provides the ability to remove
biological growth, debris and other materials that have accumulated
on the material. In particular, one of many advantages of the laser
shop 1053 being associated with the vessel is that it may be able
to reduce, or eliminate, the need for any further processing or
special handling requirements for the removed platform material,
structures or components. The laser system decommissioning system
has the ability to process the removed material offshore rendering
it to a size and form that has substantially increased value as
scrap metal for recycling and reuse.
[0131] Turning now to FIG. 1F, the final structures of the platform
have been removed, sectioned, and hauled away from the site. Thus,
the jacket 1002 has been hoisted from the seafloor 1010. The
template 1019 has been removed. The piles 1013, 1014 (and the other
two piles not seen in the FIGS) have been cut at a predetermined
depth below the seafloor (e.g., from 5 to 20 feet, and preferably
15 feet) by the laser cutting tool. The upper sections of the cut
piles are then removed from the seafloor. In this manner the laser
removal system and method of the present invention has provided for
the sectioning, hoisting, and removal of all material associated
with the platform and wells from above the surface of the water, in
the body of water, and to a predetermined depth below the seafloor.
Generally, the piles will be removed first before the jacket
structure if the annulus is not grouted.
[0132] Generally, the piles are hollow structures, or at least have
an internal cavity that extends from the jacket interface to at
least the predetermined depth below the seafloor for cutting and
removal of the pile. Thus, either or both of the inside-to-outside
cutting method and beam path or the outside-to-inside cutting
method and beam path may be employed. If the outside-to-inside
cutting method and beam path are used, the earth below the seafloor
and surrounding the pile should be removed to just below the
predetermined cutting depth to enable the laser cutting tool to
have access to the pile.
[0133] If the piles are solid structures (including for example a
tubular partially filled or completely filled with cement), in the
area or depth below seafloor cuts are intended to be made, then the
outside-to-inside method and beam path may be utilized. The earth
below the seafloor in this area should be removed to provide access
for the laser cutting tool. In solid-pile situations, variations of
the inside-to-outside method and beam path may still be utilized.
For example, the jacket, caisson, or other outer structure to the
pile may have an annulus that provides access for the laser cutting
tool. In this manner, the laser cutting tool may be used to cut the
pile from within the annulus, as well as, cut the outer structure
from within the annulus. If the annulus is filled with grout,
cement, or is too small or restrictive for the placement of the
laser tool within the annulus, then the laser tool may be used to
cut, remove, enlarge or otherwise open up the annulus, for the
laser cutting tool to obtain access into the annulus down to the
predetermined depth below the seafloor.
[0134] For piles, as well as for other solid structures that need
to be removed from above the seafloor, below the seafloor, or both,
a boring, radially cutting and, sectioning method may be employed.
In this method, the laser beam path is first directed along the
length, and preferably along the axis, of the structure to be
removed, e.g., the laser beam would be directed downwardly at the
center of a vertical member. The laser would bore a hole,
preferably along the axis of the structure, and the laser cutting
tool would move into and down this axial hole. At a point where the
axial hole was of sufficient depth, the tool would perform a radial
cut of the structure, i.e., an inside-to-outside cut with the laser
beam path traveling from inside the axial hole, to the interior
surface of the axial hole, through the structure, and through the
outer surface of the structure. This radial cut would sever (or
partially sever in a predetermined manner as discussed above) the
structure. The laser tool would be removed to a safe position and
the severed section of the structure removed. The depth of the
axial hole may be used to determine the size of the severed section
that will be removed. Thus, in general, longer axial holes will
give rise to larger and heavier severed sections. Preferably, the
radial cut does not occur at precisely the bottom of the axial
hole. Instead, if the radial cut is performed slightly above, or
above, the bottom of the axial hole, the remaining portion of the
hole, after the severed section is removed, may be used as a pilot
hole to continue the axial hole for the removal at the next section
of the structure.
[0135] It is noted that the laser removal system, methods, tools
and devices of the present inventions may be used in whole, or in
part, in conjunction with, in addition to, or as an alternative, in
whole, or in part, to existing methodologies for the removal of
offshore structures without departing from the spirit and scope of
the present inventions. Further, it is noted that the laser removal
system, methods, tools and devices of the present inventions may be
used in whole, or in part, in conjunction with, in addition to, or
as an alternative, in whole or in part, to existing methodologies
to remove or repair only a portion of an offshore structure without
departing from the spirit and scope of the present inventions.
Additionally, it is noted that the sequence or time of the various
steps, activities and methods or removal (whether solely based on
the laser removal system, methods, tools and devices or in
conjunction with existing methodologies) may be varied, repeated,
sequential, consecutive and combinations and variations of these,
without departing from the spirit and scope of the present
inventions.
[0136] It is preferable that the assemblies, conduits, support
cables, laser cutters and other subsea components associated with
the operation of the laser cutters, should be constructed to meet
the pressure and environmental requirements for the intended use.
The laser cutter head and optical related components, if they do
not meet the pressure requirements for a particular use, or if
redundant protection is desired, may be contained in or enclosed by
a structure that does meet these requirements. For deep and
ultra-deep water uses, the laser cutter and optics related
components should preferably be capable of operating under
pressures of 1,000 psi, 2,000 psi, 4,500 psi, 5,000 psi or greater.
The materials, fittings, assemblies, useful to meet these pressure
requirements are known to those of ordinary skill in the offshore
drilling arts, related sub-sea Remote Operated Vehicle ("ROV")
arts, and in the high power laser art.
[0137] The laser cutting tools may also have monitoring and sensing
equipment and apparatus associated with them. Such monitoring and
sensing equipment and apparatus may be a component of the tool, a
section of the tool, integral with the tool, or a separate
component from the tool but which still may be operationally
associated with the tool, and combinations and variations of these.
Such monitoring and sensing equipment and apparatus may be used to
monitor and detect, the conditions and operating parameters of the
tool, the high power laser fiber, the optics, any fluid conveyance
systems, the laser cutting head, the cut, and combinations of these
and other parameters and conditions. Such monitoring and sensing
equipment and apparatus may also be integrated into or associated
with a control system or control loop to provide real time control
of the operation of the tool. Such monitoring and sensing equipment
may include by way of example: the use of an optical pulse, train
of pulses, or continuous signal, that are continuously monitored
that reflect from the distal end of the fiber and are used to
determine the continuity of the fiber; the use of the fluorescence
and black body radiation from the illuminated surface as a means to
determine the continuity of the optical fiber; monitoring the
emitted light as a means to determine the characteristics, e.g.,
completeness, of a cut; the use of ultrasound to determine the
characteristics, e.g., completeness, of the cut; the use of a
separate fiber to send a probe signal for the analysis of the
characteristics, e.g., of the cut; and a small fiber optic video
camera may be used to monitor, determine and confirm that a cut is
complete. These monitoring signals may transmit at wavelengths
substantially different from the high power signal such that a
wavelength selective filter may be placed in the beam path uphole
or downhole to direct the monitoring signals into equipment for
analysis.
[0138] To facilitate some of these monitoring activities an Optical
Spectrum Analyzer or Optical Time Domain Reflectometer or
combinations thereof may be used. For example, an AnaritsuMS9710C
Optical Spectrum Analyzer having: a wavelength range of 600 nm-1.7
microns; a noise floor of 90 dBm @ 10 Hz, -40 dBm @ 1 MHz; a 70 dB
dynamic range at 1 nm resolution; and a maximum sweep width: 1200
nm and an Anaritsu CMA 4500 OTDR may be used.
[0139] The efficiency of the laser's cutting action, as well as the
completion of the cut, can also be determined by monitoring the
ratio of emitted light to the reflected light. Materials undergoing
melting, spallation, thermal dissociation, or vaporization will
reflect and absorb different ratios of light. The ratio of emitted
to reflected light may vary by material further allowing analysis
of material type by this method. Thus, by monitoring the ratio of
emitted to reflected light material type, cutting efficiency,
completeness of cut, and combinations and variation of these may be
determined. This monitoring may be performed uphole, downhole, or a
combination thereof. Further, a system monitoring the reflected
light, the emitted light and combinations thereof may be used to
determine the completeness of the laser cut. These, and the other
monitoring systems, may be utilized real-time as the cut is being
made, or may be utilized shortly after the cut has been made, for
example during a return, or second rotation of the laser tool, or
may be utilized later in time, such as for example with a separate
tool.
[0140] A preferable embodiment of a system for monitoring and
confirming that the laser cut is complete and, thus, that the laser
beam has severed the member, is a system that utilizes the color of
the light returned from the cut can be monitored using a collinear
camera system or fiber collection system to determine what material
is being cut. In the offshore environment it is likely that this
may not be a clean signal. Thus, and preferably, a set of filters
or a spectrometer may be used to separate out the spectrum
collected by the downhole sensor. This spectra can be used to
determine in real-time, if the laser is cutting metal, concrete or
rock; and thus provide information that the laser beam has
penetrated the member, that the cut is in progress, that the cut is
complete and thus that the member has been severed.
[0141] The conveyance structure may be: a single high power optical
fiber; it may be a single high power optical fiber that has
shielding; it may be a single high power optical fiber that has
multiple layers of shielding; it may have Mo, three or more high
power optical fibers that are surrounded by a single protective
layer, and each fiber may additionally have its own protective
layer; it may contain or have associated with the fiber a support
structure which may be integral with or releasable or fixedly
attached to optical fiber (e.g., a shielded optical fiber is
clipped to the exterior of a metal cable and lowered by the cable
into a borehole); it may contain other conduits such as a conduit
to carry materials to assist a laser cutter, for example gas, air,
nitrogen, oxygen, inert gases; it may have other optical or metal
fiber for the transmission of data and control information and
signals; it may be any of the combinations and variations
thereof.
[0142] The conveyance structure transmits high power laser energy
from the laser to a location where high power laser energy is to be
utilized or a high power laser activity is to be performed by, for
example, a high power laser tool. The conveyance structure may, and
preferably in some applications does, also serve as a conveyance
device for the high power laser tool. The conveyance structure's
design or configuration may range from a single optical fiber, to a
simple to complex arrangement of fibers, support cables, shielding
on other structures, depending upon such factors as the
environmental conditions of use, performance requirements for the
laser process, safety requirements, tool requirements both laser
and non-laser support materials, tool function(s), power
requirements, information and data gathering and transmitting
requirements, control requirements, and combinations and variations
of these.
[0143] The conveyance structure may be, for example, coiled tubing,
a tube within the coiled tubing, wire in a pipe, fiber in a metal
tube, jointed drill pipe, jointed drill pipe having a pipe within a
pipe, or may be any other type of line structure, that has a high
power optical fiber associated with it. As used herein the term
"line structure" should be given its broadest meaning, unless
specifically stated otherwise, and would include without
limitation: wireline; coiled tubing; slick line; logging cable;
cable structures used for completion, workover, drilling, seismic,
sensing, and logging; cable structures used for subsea completion
and other subsea activities; umbilicals; cables structures used for
scale removal, wax removal, pipe cleaning, casing cleaning,
cleaning of other tubulars; cables used for ROV control power and
data transmission; lines structures made from steel, wire and
composite materials, such as carbon fiber, wire and mesh; line
structures used for monitoring and evaluating pipeline and
boreholes; and would include without limitation such structures as
Power & Data Composite Coiled Tubing (PDT-COIL) and structures
such as those sold under the trademarks Smart Pipe and
FLATpak.RTM..
[0144] High powered conveyance structures and handling apparatus
are disclosed and taught in US Patent Application Publications
2010/0044106, 2010/0044103, 2010/0044105 and 2010/0215326 and in
pending U.S. patent application Ser. No. 12/840,978, and U.S.
patent application Ser. No. 13/210,581, the entire disclosures, of
each, of which are incorporated herein by reference.
[0145] High power long distance laser fibers, which are disclosed
in detail in US Patent Application Publications 2010/0044106,
2010/0044103, 2010/0044105 and 2010/0215326 and in pending U.S.
patent application Ser. No. 12/840,978, the entire disclosures of
each of which are incorporated herein by reference, break the
length-power-paradigm, and advance the art of high power laser
delivery beyond this paradigm, by providing optical fibers and
optical fiber cables (which terms are used interchangeably herein
and should be given their broadest possible meanings, unless
specified otherwise), which may be used as, in association with, or
as a part of conveyance structures, that overcome these and other
losses, brought about by nonlinear effects, macro-bending losses,
micro-bending losses, stress, strain, and environmental factors and
provides for the transmission of high power laser energy over great
distances without substantial power loss.
[0146] Embodiments and teachings regarding high power optical fiber
cable, fibers and the systems and components for delivering high
power laser energy, separately or in conjunction with other
materials, e.g., fluids, data or control information, over great
distances from the laser to a remote location for use by a tool are
disclosed and taught in the following U.S. patent applications and
US Patent Application Publications: Publication No. 2010/0044106,
Publication No. 2010/0044014, Publication No. 2010/0044103,
Publication No. 2010/0215326, Publication No. 2012/0020631 and Ser.
No. 13/210,581, the entire disclosures of each of which are
incorporated herein by reference. These and other embodiments may
be used as umbilicals, tethers, conveyance devices, deployment and
retrieval devices, devices to transmit work fluids and returns of
waste materials, devices to transmit the high power laser beam,
devices to send and receive data and information including control
information, and combinations and variations of these in relation
to or conjunction with the laser tool.
[0147] Laser Cutting Tools and Devices
[0148] The laser cutting tools and devices that may be utilized for
the present removal methods and with, or as a part of, the present
removal systems, in general, may have a section for receiving the
high power laser energy, such as for example, from a high power
connector on a high power fiber, or from an umbilical having a
fluid path and a high power fiber. Embodiments of high power laser
connectors and couplers are disclosed and taught in U.S. patent
application Ser. No. 13/486,795, the entire disclosure of which is
incorporated herein by reference. Although single fiber tools and
devices are described herein, it should be understood that a
cutting tool or device may receive high power laser energy from
multiple fibers. In general, the laser cutting tools and devices
may have one, or more, optics package or optics assemblies, which
shape, focus, direct, re-direct and provide for other properties of
the laser beam, which are desirable or intended for a cutting
process. Embodiments of high power laser optics packages are
disclosed and taught in U.S. patent application Ser. No.
13/403,132, the entire disclosure of which is incorporated herein
by reference. In general, the laser cutting tools and devices may
also have one or more laser cutting heads, having for example a
fluid jet, or jets, associated with the laser beam path that laser
beam takes upon leaving the tool and traveling toward the material
to be cut, e.g., the inside of a conductor. Embodiments of high
power laser cutting tools, devices and cutting heads are disclosed
and taught in the following U.S. patent applications: Publication
No. 2012/0074110; Ser. No. 61/605,429; and, Ser. No. 61/605,434,
the entire disclosures of each of which are incorporated herein by
reference.
[0149] In general, these associated fluid jets in the laser cutting
heads find greater applicability and benefit in cutting
applications that are being conducted in, or through, a liquid or
debris filled environment, such as e.g., an outside-to-inside cut
where sea water is present, or an inside-to-outside cut where
drilling mud is present. The fluid jets may be a liquid, a gas, a
combination of annular jets, where the inner annular jet is a gas
and the outer is a fluid, where the inner annular jet and outer
annular jets are liquids having predetermined and preferably
different indices of refraction. The fluid jets may be a series of
discrete jets that are substantially parallel, or converging fluid
jets and combinations and variations of these.
[0150] Thus, for example an annular gas jet, using either air,
oxygen, nitrogen or another cutting gas, may have a high power
laser beam path within the jet. As this jet is used to perform a
linear cut or kerf, a second jet, which trails just behind the gas
jet having the laser beam, is used. The paths of these jets may be
essentially parallel, or they may slightly converge or diverge
depending upon their pressures, laser power, the nature of the
material to be cut, the stand off distance for the cut, and other
factors.
[0151] For applications above the surface of the body of water, and
in particular in the laser shop that is associated with the vessel,
commercially available high power laser cutters may be used,
provided that they are, or have been sufficiently protected, to
withstand the offshore environment and conditions.
[0152] Additionally, it may be desirable for the laser cutting
tools, and especially subsea tools, and preferably in particular
tools that may be used in the interior of a jacket member, inside
of tubulars, or inside of a conductor, or in other similarly
confined and difficult to observe spaces, to have other mechanical,
measuring and monitoring components, such as a centralizer,
packers, valves for directing cement, valves for pressure testing,
a locking device, and sensing devices to determined for example,
the conditions of a cut or position of the tool.
[0153] Turning to FIG. 2 there is provided a schematic of an
embodiment of a laser cutting tool 2000 having a longitudinal axis
shown by dashed line 2008. The laser cutting tool 2000 has a
conveyance termination section 2001. The conveyance termination
section 2001 would receive and hold, for example, a composite high
power laser umbilical, a coil tube having for example a high power
laser fiber and a channel for transmitting a fluid for the laser
cutting head, a wireline having a high power fiber, or a slick line
and high power fiber. The laser tool 2000 has an anchor and
positioning section 2002. The anchor and positioning section 2002
may have a centralizer, a packer, or shoe and piston or other
mechanical, electrical, magnetic or hydraulic device that can hold
the tool in a fixed and predetermined position longitudinally,
axially or both. The section may also be used to adjust and set the
stand off distance that the laser head is from the surface to be
cut. The laser tool 2000 has a motor section 2003, which may be an
electric motor, a step motor, a motor driven by a fluid, or other
device to rotate the laser cutter head, or cause the laser beam
path to rotate. In this configuration the laser fiber, and fluid
path, if a fluid is used in the laser head, must pass by or through
the motor section 2003. Motor, optic assemblies, and beam and fluid
paths of the types that are disclosed and taught in the following
U.S. patent application Ser. No. 13/403,509; Ser. No. 61/403,287;
Publication No. 2012/0074110; Ser. No. 61/605,429; Ser. No.
61/605,434; and, Ser. No. 13/403,132, may be utilized, the entire
disclosures of each of which are incorporated herein by reference.
There is provided an optics section 2004, which for example, may
shape and direct the beam and have optical components such as a
collimating element or lens and a focusing element or lens. Optics
assemblies, packages and optical elements disclosed and taught in
the following U.S. patent application Ser. No. 13/403,132; and,
Ser. No. 61/446,040 may be utilized, the entire disclosure of each
of which is incorporated herein by reference. There is provided a
laser cutting head section 2005, which directs and moves the laser
beam along a laser beam path 2007. In this embodiment the laser
cutting head 2005 has a laser beam exit 2006. In operation the
laser beam path may be rotated through 360 degrees to perform a
complete circumferential cut of a tubular. (It is noted that the
laser beam path may be, for example: rotated a single revolution in
one direction, e.g., clockwise; rotated in a reciprocal manner,
e.g., clockwise for a number of degrees and then counter clockwise
for the same, greater or lessor degrees; rotated in multiple
revolutions, e.g., 11/2 revolutions, 2 revolutions, 3.75
revolutions, 4 revolutions, or more; and combinations and
variations of these.) The laser beam path may also be moved along
the axis of the tool. The laser beam path also may be scanned or
otherwise moved in a pattern during propagation or delivery of the
laser beam. In this manner, circular cuts, windows and perforations
may be made to a tubular, support member, or for example a
conductor. In the embodiment of FIG. 2, as well as other
embodiments, the laser beam path 2007 forms a 90 degree angle with
the axis of the tool 2008. This angle could be greater than 90
degrees or less then 90 degrees.
[0154] Turning to FIG. 3, there is shown an embodiment of a laser
cutting tool 3000. The laser cutting tool 3000 has a conveyance
termination section 3001, an anchoring and positioning section
3002, a motor section 3003, an optics package 3004, an optics and
laser cutting head section 3005, a second optics package 3006, and
a second laser cutting head section 3007. The conveyance
termination section would receive and hold, for example, a
composite high power laser umbilical, a coil tube having for
example a high power laser fiber and a channel for transmitting a
fluid for the laser cutting head, a wireline having a high power
fiber, or a slick line and high power fiber. The anchor and
positioning section may have a centralizer, a packer, or shoe and
piston or other mechanical, electrical, magnetic or hydraulic
device that can hold the tool in a fixed and predetermined position
both longitudinally and axially. The section may also be used to
adjust and set the stand off distance that the laser head is from
the surface to be cut. The motor section may be an electric motor,
a step motor, a motor driven by a fluid or other device to rotate
one or both of the laser cutting heads or cause one or both of the
laser beam paths to rotate. Motor, optic assemblies, and beam and
fluid paths of the types that are disclosed and taught in the
following U.S. patent application Ser. No. 13/403,509; Ser. No.
61/403,287; Publication No. 2012/0074110; Ser. No. 61/605,429; Ser.
No. 61/605,434; and, Ser. No. 13/403,132, may be utilized, the
entire disclosures of each of which are incorporated herein by
reference. There is provided an optics section 3004, which for
example, may shape and direct the beam and have optical components
such as a collimating element or lens and a focusing element or
lens. Optics assemblies, packages and optical elements disclosed
and taught in the following U.S. patent application Ser. No.
13/403,132; and, Ser. No. 61/446,040 may be utilized, the entire
disclosure of each of which is incorporated herein by reference.
The optics and laser cutting head section 3005 has a mirror 3040.
The mirror 3040 is movable between a first position 3040a, in the
laser beam path, and a second position 3040b, outside of the laser
beam path. The mirror 3040 may be a focusing element. Thus, when
the mirror is in the first position 3040a, it directs and focuses
the laser beam along beam path 3020. When the mirror is in the
second position 3040b, the laser beam passes by the mirror and
enters into the second optics section 3006, where it may be shaped
into a larger circular spot (having a diameter greater than the
tools diameter), a substantially linear spot, or an elongated
epical pattern, as well as other spot or pattern shapes and
configurations, for delivery along beam path 3030. The tool of the
FIG. 3 embodiment may be used, for example, in the boring, radially
cutting and, sectioning method discussed herein, wherein beam path
3030 would be used for axial boring of a structure and beam path
3020 would be used for the axial cutting and segmenting of the
structure. Like the embodiment of FIG. 2, the laser beam path 3020
may be rotated and moved axially. The laser beam path 3030 may also
be rotated and preferably should be rotated if the beam pattern is
other than circular and the tool is being used for boring. The
embodiment of FIG. 3 may also be used to clear, pierce, cut, or
remove junk or other obstructions from the bore hole to, for
example, facilitate the pumping and placement of cement plugs
during the plugging of a bore hole.
[0155] Turning to FIG. 4, there is provided a schematic of an
embodiment of a laser cutting tool. The laser tool 4701 has a
conveyance structure 4702, which may have an E-line, a high power
laser fiber, and an air pathway. The conveyance structure 4702
connects to the cable/tube termination section 4703. The tool 4701
also has an electronics cartridge 4704, an anchor section 4705, a
hydraulic section 4706, an optics/cutting section (e.g., optics and
laser head) 4707, a second or lower anchor section 4708, and a
lower head 4709. The electronics cartridge 4704 may have a
communications point with the tool for providing data transmission
from sensors in the tool to the surface, for data processing from
sensors, from control signals or both, and for receiving control
signals or control information from the surface for operating the
tool or the tools components. The anchor sections 4705, 4708 may
be, for example, a hydraulically activated mechanism that contacts
and applies force to the borehole. The lower head section 4709 may
include a junk collection device, or a sensor package or other down
hole equipment. The hydraulic section 4706 has an electric motor
4706a, a hydraulic pump 4606b, a hydraulic block 4706c, and an
anchoring reservoir 4706d. The optics/cutting section 4707 has a
swivel motor 4707a and a laser head section 4707b. Further, the
motors 4704a and 4706a may be a single motor that has power
transmitted to each section by shafts, which are controlled by a
switch or clutch mechanism. The flow path for the gas to form the
fluid jet is schematically shown by line 4713. The path for
electrical power is schematically shown by line 4712. The laser
head section 4707b preferably may have any of the laser fluid jet
heads provided in this specification, it may have a laser beam
delivery head that does not use a fluid jet, and it may have
combinations of these and other laser delivery heads that are known
to the art.
[0156] FIGS. 5A and 5B show schematic layouts for cutting systems
using a two fluid dual annular laser jet. Thus, there is an uphole
section 4801 of the system 4800 that is located above the surface
of the earth, or outside of the borehole. There is a conveyance
section 4802, which operably associates the uphole section 4801
with the downhole section 4803. The uphole section has a high power
laser unit 4810 and a power supply 4811. In this embodiment, the
conveyance section 4802 is a tube, a bunched cable, or umbilical
having two fluid lines and a high power optical fiber. In the
embodiment of FIG. 6A, the downhole section has a first fluid
source 4820, e.g., water or a mixture of oils having a
predetermined index of refraction, and a second fluid source 4821,
e.g., an oil having a predetermined and different index of
refraction from the first fluid. The fluids are fed into a dual
reservoir 4822 (the fluids are not mixed and are kept separate as
indicated by the dashed line), which may be pressurized and which
feeds dual pumps 4823 (the fluids are not mixed and are kept
separate as indicated by the dashed line). In operation the two
fluids 4820, 4821 are pumped to the dual fluid jet nozzle 4826. The
high power laser beam, along a beam path enters the optics 4824, is
shaped to a predetermined profile, and delivered into the nozzle
4826. In the embodiment of FIG. 5B a control head motor 4830 has
been added and controlled motion laser jet 4831 has been employed
in place of the laser jet 4826. Additionally, the reservoir 4822
may not be used, as shown in the embodiment of FIG. 5B.
[0157] Turning to FIGS. 6A and 6B, there is shown schematic layouts
for cutting systems using a two fluid dual annular laser jet. Thus,
there is an uphole section 4901 of the system 4900 that is located
above the surface of the earth, or outside of the borehole. There
is a conveyance section 4902, which operably associates the uphole
section 4901 with the downhole section 4903. The uphole section
4901 has a high power laser unit 4910 and a power supply 4911 and
has a first fluid source 4920, e.g., a gas or liquid, and a second
fluid source 4921, e.g., a liquid having a predetermined index of
refraction. The fluids are fed into a dual reservoir 4922 (the
fluids are not mixed and are kept separate as indicated by the
dashed line), which may be pressurized and which feeds dual pumps
4923 (the fluids are not mixed and are kept separate as indicated
by the dashed line). In operation the two fluids 4920, 4921 are
pumped through the conveyance section 4902 to the downhole section
4903 and into the dual fluid jet nozzle 4926. In this embodiment,
the conveyance section 4902 is a tube, a bunched cable, or
umbilical. For FIG. 6A, the conveyance section 4902 would have two
fluid lines and a high power optical fiber. In the embodiment of
FIG. 6B, the conveyance section 4902 would have two fluid lines, an
electric line and a high power optical fiber. In the embodiment of
FIG. 6A, the downhole section 4903 has an optics assembly 4924 and
a nozzle 4925. The high power laser beam, along a beam path enters
the optics assembly 4924, where it may be shaped to a predetermined
profile, and delivered into the nozzle 4926. In the embodiment of
FIG. 6B, a control head motor 4930 has been added and controlled
motion laser jet 4931 has been employed in place of the laser jet
4926. Additionally, the reservoir 4922 may not used as shown in the
embodiment of FIG. 6B.
[0158] Down hole tractors and other types of driving or motive
devices may be used with the laser tools to both advance or push
the laser down into or along a member to be cut, or to pull the
laser tool from the member. Thus, for example a coil tubing
injector, an injector assembly having a goose neck and/or
straightener, a rotating advancement and retraction device, a dog
and piston type advancement and retraction device, or other means
to push or pull a coil tubing, a tubular, a drill pipe, integrated
umbilical or a composite tubing, which is affixed to the laser
tool, may be utilized. In this manner the tool may be precisely
positioned for laser cutting. Further, when performing an
inside-to-outside cut, if the pile, or other structure is filled
with mud, or other semi-solid material, the laser tool may be
forced through, e.g., snubbed, the mud to the location where the
laser cut is to be performed. For an outside-to-inside cut, this
type of forcing may also be utilized when there is mud, debris or
similar semi-solid materials present around the outside of the cut
that the tool may be pushed through. In this manner, the laser cut
could be performed without having to go through the added expense
and time of removing the mud to expose the cut area. It is noted
that a winch, gravity and other means of lowering or advancing the
laser tool to the desired position may be employed. These devices
can be used to advance the laser tool to a specific location where
a laser process, e.g., a laser cut is needed, or they can be used
to move the tool, and thus the laser head and beam path to deliver
a particular pattern to make a particular cut. Further, these
devices may be incorporated into, or otherwise associated with,
platforms or structures that are attached to, either permanently or
releasably to the top of the pile, well or other structure that is
to be cut.
[0159] Turning to FIG. 7, there is provided an embodiment of a
laser cutting tool 7002 that may be used for example to perform an
outside-to-inside cut. The laser cutting tool 7002 is shown
attached to a section of a vertical support member 7001 of a jacket
of a fixed platform. The tool 7002 has a hinge device 7003 and a
securing or locking means 7004. The tool 7002 has an umbilical 7005
for providing high power laser energy to the tool, as well as, any
fluids, electricity or other materials or data used in the cutting
operation. The tool may have one, two or more laser cutting heads,
not shown in the figure, that are located within the laser tool. In
operation the laser tool is closed around the vertical member and
secured together. The laser cutting head(s) would then move around
the interior of the tool delivering the laser beam in a circular
pattern around the exterior of the vertical member. This embodiment
may also be associated with a tractor, guide wires, or a lifting
mechanism, which would permit it to be moved, or move, along a
member that it is attached to, and thus go to a different location
to perform cuts without having to be unsecured and resecured.
[0160] Turning to FIG. 8, there is provided an embodiment of a
laser cutting tool 8072 that is associated with a Remote Operated
Vehicle (ROV) 8070. Thus, there is provided in this embodiment a
vessel 8051, a laser module 8055, an umbilical 8071 (which provides
among other things an optical connection between the laser and the
cutter 8072). The ROV 8070 is shown in a body of water 8011, below
the surface 8012 and moving toward a jacket 8002 that is fixed to
the sea floor 8010 and which has been partially removed. The laser
cutting tool 8072 may be used to cut various sections and members
of the jacket 8002. It being understood that, with this embodiment,
as well as other embodiments provided in this specification,
although sub-sea jackets and piles are illustrated, the
embodiments, tools, methods and systems may be utilized to cut and
remove other types and kinds of structures or materials, sub-sea,
land based or otherwise, e.g., mooring chains, subsea pipelines, or
control umbilicals.
[0161] Turning to FIG. 9, there is provided an embodiment of a
tubular cutting station that has a platform 9000. The platform 9000
may be a rig floor, or it may be attached to, or part of a vessel,
such as a decommissioning vessel. The platform 9000 has a hoisting
means 9001 associated with it. As shown in the figure, the hoisting
means has lifted a member 9002, which for example could be a
conductor. The member 9002 extends above and below (not shown) the
platform and needs to be sectioned for further handling. The
platform has a locking and engaging device 9003, e.g., along the
lines of a spider for use with risers or other large tubulars, or a
hole and pin arrangement, that holds the lower section of the
member 9002 and prevents it from falling once the cut has been
made. In this embodiment, there are provided two laser cutting
devices 9004, 9005. These two devices 9004, 9005 each have a laser
cutting assembly 9006, 9007, which have laser cutting heads (not
shown), and a high power laser umbilical 9008, 9009. In operation,
a tubular or member 9002 is pulled up through the platform by the
hoist 9001. The tubular is then locked and held by the engagement
device 9003. The laser cutting devices 9004, 9005 then move the
laser cutting assemblies 9006, 9007 into engagement with the
tubular. (A predetermined standoff distance may be utilized, or the
assemblies may be in direct contact with the tubular.) Preferably,
the cutting devices 9004, 9005 are in optical sealing contact with
the tubular. In this manner the cutting environment and the system
may be classified as a Class 1 system and have the safety and ease
of use benefits of such a system. The entire laser cutting device
9004, 9005 or both, may for example slide toward the tubular on
tracks, or the device may have a stationary base and movable arm,
such a robotic arm, that moves the cutting assembly into position.
The laser head(s) then deliver a laser beam(s) to cut the tubular.
The upper section of the tubular is then removed by the hoist. A
lifting device, e.g., holes and pins, is then associated with the
remaining lower section of the tubular, the tubular is then hoisted
up into position and the cutting process is repeated. For a
conductor that may be as much as 2,000 or 3,000 feet, this process
may have to be repeated many times, depending upon the lifting
height or clearance of the hoist (e.g., about 50, 100 or 200
feet).
[0162] Turning to FIG. 10, there is shown an embodiment of a laser
shop and laser beam distribution system for use on, or in
conjunction with, a laser decommissioning system. In general, the
laser shop and system many have a single or multiple lasers that
are optically associated with cutting tools and devices.
Preferably, the optical association is with the use of high power
optical fibers, beam splitters, mirrors, and other such optical
components to control, determine and direct the manner in which the
laser beam is transported to various cutting tools and devices.
There is provided, by way of example, a high power laser 1001, that
has a high power optical fiber 1060 for transporting the laser beam
from the laser (the arrows show the direction of travel or
propagation, of the laser beam in the fibers). The optical fiber
1060 is optically associated with a movable mirror 1080 or other
type of beam directing or shifting device, such as a movable beam
splitter. The mirror 1080 may be moved from a first position 1080b
to a second position 1080a. When the mirror 1080 is in position
1080a (i.e., removed from the beam path) all of the high power
laser energy is transmitted to fiber 1061, which is optically
associated with assembly 1074. Assembly 1074 may be for example a
spool, a tool such as shown in FIGS. 2-8, or both. When the beam
splitter is in position 1080b, (i.e., in the beam path) a portion
of, or all of the laser beam is transmitted along fiber 1062 (with
any remaining portion of the laser beam being transmitted along
fiber 1061. (The ratios of power transmitted between fibers 1062
and 1061, when device is in position 1080b may be for example about
100:0, 50:50, 40:60, 60:40 or other ratios of power between fiber
1062 and fiber 1061.) Fiber 1062 is optically associated with a
first fixed beam splitter 1081. First fixed beam splitter 1081 is
optically associated with fiber 1063 and fiber 1072. Fiber 1063 is
optically associated with a second fixed beam splitter 1082, which
in turn is optically associated with fiber 1071 and fiber 1064.
Fiber 1064 is optically associated with a third fixed beam splitter
1083, which is optically associated with fiber 1070 and a beam dump
(not shown). The fixed beam splitters 1081, 1082, 1083 may have any
ratio of power transmission that is need for the tools or process
that the tools associated with the respective fibers may need.
Fiber 1072 is optically associated with laser device 1073, which
for example may be a hand held laser cutting tool.
[0163] Optical fibers 1070 and 1071 provide high power laser energy
to laser cutting devices 1004, 1006 that are shown in an associated
laser shop layout 1002. The laser shop layout 1002 has a transport
device 1003 that has a driver 1008. The transport device, for
example, may be a conveyor system, a winch and rail system, or a
tubular conveyance system along the lines of a catwalk. The laser
cutting devices 1004, 1006 have laser cutting heads 1005, 1007,
which move along the cutting devices as shown by the arrows. In
operation, a member to be cut is moved into the laser shop layout
area, under the laser cutting devices. The laser heads are then
moved across the member, delivering a laser beam along a beam path
to the member and severing it.
[0164] The layout of fibers, movable beam splitters, fixed beam
splitters, laser and cutters may be varied and additional or other
optical components may be used with out departing from the spirit
and scope of this invention. Thus, for example, each tool or cutter
could have a dedicated laser. The laser shop could have a dedicated
laser and the other tools could operate from a second laser. In
this later example only two lasers would be required, and if one
should break, the other could be used to run the entire system
using a configuration like the FIG. 10 embodiment. Additionally, a
dedicated laser module may be used, which module may further be
specifically designed and constructed for a particular application
or system.
[0165] Thus, for example, the laser cutting tools, and variations
and combinations of these tools, disclosed and taught in the
following U.S. patent applications and U.S. Patent Application
Publications: Publication No. 2010/0044104; Ser. No. 13/403,509;
Ser. No. 13/366,882; Publication No. 2012/0074110; Ser. No.
61/605,429; Ser. No. 61/605,434; Publication No. 2012/0067643; Ser.
No. 61/378,910; Ser. No. 61/374,594; and Ser. No. 13/347,445, the
entire disclosure of each of which is incorporated herein by
reference, may be utilized.
[0166] The arrangement and relative positions of sections and
components of the laser tools, devices and configurations of the
embodiments herein may be varied, intermixed, and additional
sections or components may be used and employed without departing
from the scope and spirit of the inventions.
[0167] Laser Cutting Heads
[0168] Configurations of optical elements for collimating and
focusing the laser beam can be employed with laser cutting heads to
provide the desired beam properties for a particular application or
tool configuration. A further consideration, however, is the
management of the optical affects of fluids or debris that may be
located within the beam path between laser tool and the work
surface, e.g., the surface of the material to be cut.
[0169] Thus, it is advantageous to minimize the detrimental effects
of such fluids and materials and to substantially ensure, or
ensure, that such fluids do not interfere with the transmission of
the laser beam, or that sufficient laser power is used to overcome
any losses that may occur from transmitting the laser beam through
such fluids. To this end, mechanical, pressure and jet type systems
may be utilized to reduce, minimize or substantially eliminate the
effect of these fluids on the laser beam.
[0170] For example, mechanical devices may be used to isolate the
area where the laser operation is to be performed and the fluid
removed from this area of isolation, by way of example, through the
insertion of an inert gas, or an optically transmissive fluid, such
as a water, brine, or water solutions. The use of a fluid in this
configuration has the added advantage that it is essentially
incompressible.
[0171] Preferably, if an optically transmissive fluid is employed
the fluid will be flowing. In this manner, the overheating of the
fluid, from the laser energy passing through it, or from it
residing at the cut site, may be avoided or lessened; because the
fluid is flowing and not dwelling or residing for extended times in
the laser beam or at the cut site, where heating from laser and the
laser cut material may occur.
[0172] The mitigation and management of back reflections when
propagating a laser fluid jet through a fluid, from a cutting head
of a laser tool to a work surface, may be accomplished by several
methodologies, which are set forth in various embodiments herein.
The methodologies to address back reflections and mitigate
potential damage from them would include the use of an optical
isolator, which could be placed in either collimated space or at
other points along the beam path after it is launched from a fiber
or connector. The focal point may be positioned such that it is a
substantial distance from the laser tool; e.g., greater than 4
inches, greater than 6 inches and greater than 8 inches.
Preferably, the focus point may be beyond the fluid jet coherence
distance, thus, greatly reducing the likelihood that a focused beam
would strike a reflective surface formed between the end of the
fluid jet and the medium in which it was being propagated, e.g., a
gas jet in water. The laser beam may be configured such that it has
a very large depth of focus in the area where the work surface is
intended to be, which depth of focus may extend into and preferably
beyond the cutting tool. Additionally, the use of an active optical
element (e.g., a Faraday isolator) may be employed. Methods,
configurations and devices for the management and mitigation of
back reflections are taught and disclosed in US Patent Applications
Publication No. 2012/0074110 and Ser. No. 61/605,434, the entire
disclosure of each of which is incorporated herein by
reference.
[0173] Moreover, a mechanical snorkel like device, or tube, which
is filled with an optically transmissive fluid (gas or liquid) may
be extended between or otherwise placed in the area between the
laser tool and the work surface or area. Similarly mechanical
devices such as an extendable pivot arm may be used to shorten the
laser beam path keeping the beam closer to the cutting surface as
the cut is advanced or deepened.
[0174] A jet of high-pressure gas may be used with the laser beam.
The high-pressure gas jet may be used to clear a path, or partial
path for the laser beam. The gas may be inert, it may be air,
nitrogen, oxygen, or other type of gas that accelerates, enhances,
or controls the laser cutting processes.
[0175] The use of oxygen, air, or the use of very high power laser
beams, e.g., greater than about 1 kW, greater than about 10 kW, and
greater than about 20 kW, could create and maintain a plasma
bubble, a vapor bubble, or a gas bubble in the laser illumination
area, which could partially or completely displace the fluid in the
path of the laser beam. If such a bubble is utilized, preferably
the size of the bubble should be maintained as small as possible,
which will avoid, or minimize the loss of power density.
[0176] A high-pressure laser liquid jet, having a single liquid
stream, may be used with the laser beam. The liquid used for the
jet should be transmissive, or at least substantially transmissive,
to the laser beam. In this type of jet laser beam combination the
laser beam may be coaxial with the jet. This configuration,
however, has the disadvantage and problem that the fluid jet may
not act as a wave-guide. A further disadvantage and problem with
this single jet configuration is that the jet must provide both the
force to keep the drilling fluid away from the laser beam and be
the medium for transmitting the beam.
[0177] A compound fluid jet may be used in a laser cutting tool.
The compound fluid jet has an inner core jet that is surrounded by
annular outer jets. The laser beam is directed by optics into the
core jet and transmitted by the core jet, which functions as a
waveguide. A single annular jet can surround the core, or a
plurality of nested annular jets can be employed. As such, the
compound fluid jet has a core jet. This core jet is surrounded by a
first annular jet. This first annular jet can also be surrounded by
a second annular jet; and the second annular jet can be surrounded
by a third annular jet, which can be surrounded by additional
annular jets. The outer annular jets function to protect the inner
core jet from the drill fluid present between the laser cutter and
the structure to be cut. The core jet and the first annular jet
should be made from fluids that have different indices of
refraction. Further details, descriptions, and examples of such
compound fluid laser jets are contained in the following U.S.
Patent Applications: Publication No. 2012/0074110; Ser. No.
61/605,434; and, Ser. No. 61/378,910, the entire disclosure of each
of which is incorporated herein by reference.
[0178] The angle at which the laser beam contacts a surface of a
work piece may be determined by the optics within the laser tool or
it may be determined the positioning of the laser cutter or tool,
and combinations and variations of these. The laser tools have a
discharge end from which the laser beam is propagated. The laser
tools also have a beam path. The beam path is defined by the path
that the laser beam is intended to take, and can extend from the
laser source through a fiber, optics and to the work surface, and
would include as the laser path that portion that extends from the
discharge end of the laser tool to the material or area to be
illuminated by the laser.
[0179] In the situation where multiple annular jets are employed,
the criticality of the difference in indices of refraction between
the core jet and the first (inner most, i.e., closes to the core
jet) annular jet is reduced, as this difference can be obtained
between the annular jets themselves. However, in the multi-annular
ring compound jet configuration the indices of refraction should
nevertheless be selected to prevent the laser beam from entering,
or otherwise being transmitted by the outermost (furthest from the
core jet and adjacent the work environment medium) annular ring.
Thus, for example, in a compound jet, having an inner jet with an
index of refraction of n.sub.1, a first annular jet adjacent the
inner jet, the first annular jet having an index of refraction of
n.sub.2, a second annular jet adjacent to the first annular jet and
forming the outer most jet of the composite jet, the second annular
jet having an index of refraction of n.sub.3. A waveguide is
obtained when for example: (i) n.sub.1>n.sub.2; (ii)
n.sub.1>n.sub.3; (iii) n.sub.1<n.sub.2 and
n.sub.z>n.sub.3; and, (iv) n.sub.1<n.sub.2 and
n.sub.1>n.sub.3 and n.sub.2>n.sub.3.
[0180] The pressure and the speed of the various jets that make up
the compound fluid jet can vary depending upon the applications and
use environment. Thus, by way of example the pressure can range
from about 100 psi, to about 4000 psi, to about 30,000 psi, to
preferably about 70,000 psi, to greater pressures. However, lower
pressures may also be used. The core jet and the annular jet(s) may
be the same pressure, or different pressures, the core jet may be
higher pressure or the annular jets may be higher pressure.
Preferably, the core jet is at a higher pressure than the annular
jet. By way of example, in a multi-jet configuration the core jet
could be 70,000 psi, the second annular jet (which is positioned
adjacent the core and the third annular jet) could be 60,000 psi
and the third (outer, which is positioned adjacent the second
annular jet and is in contact with the work environment medium)
annular jet could be 50,000 psi. The speed of the jets can be the
same or different. Thus, the speed of the core can be greater than
the speed of the annular jet, the speed of the annular jet can be
greater than the speed of the core jet and the speeds of multiple
annular jets can be different or the same. The speeds of the core
jet and the annular jet can be selected, such that the core jet
does contact the drilling fluid, or such contact is minimized. The
speeds of the jet can range from relatively slow to very fast and
preferably range from about 1 m/s (meters/second) to about 50 m/s,
to about 200 m/s, to about 300 m/s and greater. The order in which
the jets are first formed can be the core jet first, followed by
the annular rings, the annular ring jet first followed by the core,
or the core jet and the annular ring being formed simultaneously.
To minimize, or eliminate, the interaction of the core with the
drilling fluid, the annular jet is created first followed by the
core jet.
[0181] In selecting the fluids for forming the jets and in
determining the amount of the difference in the indices of
refraction for the fluids, the wavelength of the laser beam and the
power of the laser beam are factors that should be considered.
Thus, for example, for a high power laser beam having a wavelength
in the 1070 nm (nanometer) range the core jet can be made from an
oil having an index of refraction of about 1.53 and the annular jet
can be made from water having an index of refraction from about
1.33 or another fluid having an index less than 1.53. Thus, the
core jet for this configuration would have an NA (numerical
aperture) from about 0.12 to about 0.95, respectively.
[0182] The number of laser cutters utilized in a configuration of
the present inventions can be a single cutter, two cutters, three
cutters, and up to and including 12 or more cutters. As discussed
above, the number of cutters depends upon several factors and the
optimal number of cutters for any particular configuration and end
use may be determined based upon the end use requirements and the
disclosures and teachings provided in this specification. The
cutters may further be positioned such that their respective laser
beam paths are parallel, or at least non-intersecting within the
center axis of the member to be cut.
[0183] Examples of laser power, fluence and cutting rates, based
upon published data, are set forth in Table I.
TABLE-US-00001 TABLE I laser Laser cutting thickness power spot
size fluence rate type (mm) (watts) (microns) (MW/cc.sup.2) Gas
(m/min) mild steel 15 5,000 300 7.1 O.sub.2 1.8 stainless 15 5,000
300 7.1 N.sub.2 1.6 steel
[0184] Turning to FIG. 12, there is provided a general schematic of
an embodiment of a high power laser cutting head using a gas jet, a
long focal length and having a large depth of field. Thus, the
laser cutting head 5501 (shown in phantom lines) is associated with
an optics assembly 5502 (partially shown and in phantom lines),
which assembly takes the laser beam from a conveyance structure,
focuses the laser beam (the optics assembly may also perform
additional or other functions to effect beam properties) and
provides the laser beam 5509 along a laser beam path 5507. The
laser beam 5509 traveling along beam path 5507 is reflected by a
reflective member, e.g., a mirror 5506 (at for example a right
angle as shown). The beam and beam path enter into nozzle 5503 that
forms a gas jet 5508. The gas jet 5508 may be, for example, air,
oxygen, nitrogen, an inert gas, a cutting gas, or a super critical
fluid. The face 5510 of the nozzle 5503 may be tapered outwardly,
as provided by surfaces 5504, 5505.
[0185] Focal lengths may vary from about 40 mm (millimeters) to
about 2,000 mm, and more preferably from about 150 mm to about
1,500 mm, depending upon the application, material type, material
thickness, and other conditions that are present during the
cutting. The jet velocity may be about 100 to about 10,000 f/s and
from about 100 to about 5,000 cf/m, depending upon the application,
material type, material thickness, and other conditions that are
present during the cutting.
[0186] The mirror may be any high power laser optic that is highly
reflective of the laser beam wavelength, can withstand the
operational pressures, and can withstand the power densities that
it will be subjected to during operation. For example, the mirror
may be made from various materials. For example, metal mirrors are
commonly made of copper, rhodium, polished and coated with polished
gold, nickel, aluminum, or silver and sometime may have dielectric
enhancement. Mirrors with glass substrates may often be made with
fused silica because of its very low thermal expansion. The glass
in such mirrors may be coated with a dielectric HR (highly
reflective) coating. The HR stack as it is known, includes of
layers of high/low index layers made of SiO.sub.2, Ta.sub.2O.sub.5,
ZrO.sub.2, MgF, Al.sub.2O.sub.3, HfO.sub.2, Nb.sub.2O.sub.5,
TiO.sub.2, Ti.sub.2O.sub.3, WO.sub.3, SiON, Si.sub.3N.sub.4, Si, or
Y.sub.2O.sub.3 (All these materials would work for may wave
lengths, including 1064 nm to 1550 nm). For higher powers, such as
50 kW actively cooled copper mirrors with gold enhancements may be
used. It further may be water cooled, or cooled by the flow of the
gas. Preferably, the mirror may also be transmissive to wavelengths
other than the laser beam wavelength. In this manner an optical
observation device, e.g., a photo diode, a camera, or other optical
monitoring and detection device, may be placed behind it.
[0187] In the embodiment of FIG. 12, the face 5510 of the nozzle is
flush with the body of the laser head 5501. The nozzle face, with
respect to the body of the laser head may be recessed, slightly
recessed, extend beyond, have an extension tube that extends beyond
and combinations and variations of these.
[0188] Although not shown in the figure, the mirror and nozzle, or
the entire head may be movable or steerable.
[0189] During operations, and in particular when the laser tool is
being operated in a fluid filled or dirty environment, the air flow
should be maintained into the laser head and out the nozzle with
sufficient pressure and flow rate to prevent environmental
contaminants or fluid from entering into the nozzle, or
contaminating the mirror or optics. A shutter, or door that may be
opened and closed may also be used to protect or seal the nozzle
opening, for example, during tripping into and out of a borehole. A
disposable cover may also be placed over the nozzle opening, which
is readily destroyed either by the force of the gas jet, the laser
beam or both. In this manner, the nozzle, mirror and optics can be
protecting during for example a long tripping in to a borehole, but
readily removed upon the commencement of downhole laser cutting
operations, without the need of mechanical opening devices to
remove the cover.
[0190] For performing downhole laser cutting operations, and in
particular the laser cutting of tubulars within a borehole the
following cutting rates may be obtained using a laser gas jet tool
with an air pressure of about 125 psi above the ambient pressure,
e.g., borehole pressure, at the nozzle (as borehole pressures
increase high gas pressures may be used), an air flow volume of
10-300 cfm (depending upon the nozzle diameter), the focal point
being about 6 inches from the nozzle face, and the surface of the
tubular being about 5 inches from the nozzle face.
TABLE-US-00002 TABLE II spot size tubular cutting laser power
diameter at wall rate at surface surface of thickness (inches/ of
tubular tubular (inches) min.) 15 kW 5 mm 1/4 30+ 15 kW 5 mm 3/8
25+ 15 kW 5 mm 1/2 10+ 20 kW 5 mm 1/2 35+ 20 kW 600 .mu.m 1/4 200
20 kW 600 .mu.m 1/2 100+ 20 kW 600 .mu.m 3/4 75+
[0191] The reflective member in the embodiment FIG. 12, as well as,
other embodiments for tools and laser cutting heading heads may be
a prism, and preferably a prism that utilizes total internal
reflection (TIR). Thus, and in general, the prism is configured
within the tool such that a high power laser beam is directed
toward a first face or surface of the prism. The prism may be made
of fused silica, sapphire, diamond, calcium chloride, or other such
materials capable of handling high power laser beams and
transmitting them with little, low or essentially no absorbance of
the laser beam. The plane of first face is essentially normal to
the laser beam and has an antireflective (AR) coating. This angle
may vary from 90 degrees, by preferably no more than 5 degrees.
Large angles of variation are contemplated, but less preferred,
because specific AR coatings and other means to address reflection,
refraction will need to be utilized. A key advantage in this
embodiment is that the AR coatings have a much lower absorption
than an (highly reflective) HR coating as a consequence there is
substantially less heating in the substrate when using and AR
coating. The entrance and exit of the prism should have AR coating
matched to the medium of transmission and the angle of incidence of
the laser beam should satisfies the TIR condition to cause the beam
to be deflected in a different direction. Multiple TIR reflections
can be used to make the total desired angle with virtually no loss,
and essentially no loss, in power at each interface.
[0192] Upon entering the prism, the laser beam travels through the
prism material and strikes a second surface or face, e.g., the
hypotenuse, of the prism. The material on the outside this second
face has an index of refraction, which in view of the angle at
which the laser beam is striking the second face, result in total
internal reflection (TIR) of the laser beam within the prism. Thus,
the laser beam travels from the second face to the third face of
the prism and leaves the prism at an angle that is about 90 degrees
to the path of the laser beam entering the prism. In this manner,
the prism utilizes TIR to change the direction of the laser beam
within the tool. Depending upon the position of the prism relative
to the incoming laser beam and other factors, the angle of the
exiting laser beam from the prism relative to the incoming laser
beam into the prism may be greater than or less than 90 degrees,
e.g., 89 degrees, 91 degrees, 92 degrees, and 88 degrees, with the
minimum angle being dependent on the refractive index of the
material and the TIR condition, etc. Further embodiments of TIR
prisms in laser tools are taught and disclosed in U.S. Patent
Application Ser. No. 61/605,434, the entire disclosure of which is
incorporated herein by reference.
[0193] Turning to FIG. 13, there is shown a perspective view of a
nozzle assembly 5901. The nozzle assembly has a first fluid inlet
5902, a second fluid inlet 5903, which are in fluid communication
with an annular chamber 5904. The annular chamber 5904 is in fluid
communication with nozzle feed passages 5905a, 5905b, 5905c, 5905d,
5905e, 5950f, 5905g. These feed passages are in fluid communication
with a nozzle cone 5906 having a nozzle tube 5907.
[0194] Turning to FIG. 14, there is shown a perspective view of a
nozzle assembly 6000. The nozzle assembly has a four fluid intakes
6002, 6003, 6004, 6005, which each feed fluid intake passages
6002a, 6003a, 6004a, 6005a. These fluid intake passage feed nozzle
6006.
[0195] FIG. 15A is a cross-sectional view of a nozzle assembly
having several ancillary chambers and FIG. 15B is a perspective
cross-section cutaway of some of the components of this nozzle
assembly. The nozzle assembly has a body 6120 that has a fluid
inlet 6102, which feeds a window flow chamber 6104 (fluid flow is
shown by arrows 6130). The fluid flows past window 6116, that has a
laser beam path 6108. The fluid flows into the nozzle chamber that
is parallel and coincident with the beam path 6108. The fluid may
also flow into annular flow access chamber 6106, which flows in
passages 6112, 6110 back to the laser beam path 6108. The laser
beam 6114 following beam path 6108 is shown in FIG. 15B.
[0196] FIGS. 16A to 16C show a nozzle 6201 that has a body 6207 and
a flow intake surface 6203. The fluid flow is shown by arrows 6204.
The fluid flows along flow surface 6203 and into opening 6202 and
tube 6206. The laser beam path 6205 travels through the opening
6202 and tube 6206. The nozzle 6201 is configured in a nozzle
assembly having inlets 6220, 6221 and a window 6222.
[0197] An example of an embodiment of a nozzle configuration for
providing a single liquid jet is provided in FIGS. 17, 17A, 17B,
17C and 17D. FIGS. 17A and 17B are transverse cross sections of the
embodiment of FIG. 17 taken along lines A-A and B-B respectively.
FIG. 17C is an enlarged view of the prism and flow passage area of
the laser head assembly of FIG. 17.
[0198] Turning to FIG. 17 there is shown a laser head assembly 1701
having a housing 1702. The housing 1702 has a fluid port 1703 for
receiving a liquid to form the liquid jet 1717 and a laser beam
path opening 1704 for receiving a laser beam. The laser beam path
1716 is shown through the laser head assembly 1701. Along the beam
path 1716, within the housing 1702, there is a prism engagement
member 1706, having a laser beam path opening 1707. The prism
engagement member 1706 is located between the prism 1705 and an
inner surface of the housing 1702. The prism 1705 is located within
the laser beam path 1716 and has a beam entry face 1726 and a beam
exit face 1725. A prism supporting and positioning member 1708 is
located between the inner surface of the housing 1702 and the face
1734 of the prism, which face is not in the laser beam path
1716.
[0199] There is a flow path creating member 1709 that has a first
curved surface 1723 and a second curved surface 1724. The exit face
1725 of the prism 1705 and the first curved surface 1723 and the
second curved surface 1724 form a liquid flow chamber 1722. There
is also a flow plug 1710 in the liquid flow chamber 1722. The flow
plug 1710 may be removed providing for the recirculation of the
liquid through recirculation ports 1718, 1719.
[0200] The laser head assembly 1701 at its bottom end has a bottom
cap 1711 and a locking ring 1713. The locking ring 1713 engages the
bottom cap 1711 and a nozzle 1712. The nozzle has an inner flow
path having three sections, a first section 1730, a second tapered
section 1713, and a third section 1732. The inner diameter of the
first section 1730 may be, for example, two, three or more times
larger than the inner diameter of the third section 1732. The
length of the second section may be, for example from about the
same as the diameter of the first section to about twice as long as
the diameter of the first section, or longer. The size and shape of
these sections depends upon factors such as the viscosity of the
liquid and the intended pressures and flow volumes of the jet.
Additionally, the profile of the laser beam is a consideration, as
the beam should not contact the nozzle components or surfaces.
Preferably the inner diameter third section 1732, which forms the
aperture for the nozzle, is from about 400 microns to about 2000
microns, and preferably about 600 microns to about 1500 microns.
The nozzle 1712 has a tip 1733 that extends beyond the bottom of
the locking ring 1713.
[0201] Referring to FIG. 17D, there is provided a cross sectional
perspective view of the laser head 1701, with its lower components
(e.g., nozzle 1712, flow path creating member 1719, locking ring
1713 and cap 1711) removed and the laser beam 1740 traveling along
beam path 1716 being shown.
[0202] In operation a liquid is pumped under pressure into flow
port 1703. The liquid flows into flow chamber 1722 and from flow
chamber 1722 into nozzle 1712. The liquid exits nozzle 1712 as a
fluid jet. The laser beam is focused by optics not shown in the
figures, and travels along beam path 1716 through opening 1704,
opening 1706 and enters into prism 1705 through prism face 1726.
The laser beam travels through prism 1705 and, if a liquid is not
present, exits prism face 1725 along beam path 1716a. Beam path
1716a travels into and through the lower components of the laser
head and if a high power laser beam traveled along that path 1716a
it would damage those components. If a liquid having a
predetermined index of refraction is present in the chamber 1722,
the laser beam will stay on and follow beam path 1716 and enter
into the liquid at face 1722 and travel into the nozzle 1712 and
exit the nozzle 1712 within the liquid jet 1717.
[0203] In order for the laser beam to travel along the entirety of
laser beam path 1716, and thus enter the nozzle, the indices of
refraction of the liquid and of the prism must be matched. By
matched it is meant that the indices are identical, essential the
same, or within about + or -5% different and within about + or -10%
different. Further, this difference should generally be small
enough as to permit the laser beam to enter into the fluid without
substantial reflections. To the extent that the indices are not
identical the angle and position of the prism 1705 and in
particular the angle of the face 1725 can be adjusted, such that
any shifting of the beam path resulting from the index change as
the beam travels from the prism to the fluid, will be compensated
for; and thus, the beam path and beam will be directed into the
nozzle and not contact any of the components of the laser head.
[0204] The configuration of face 1725, and surfaces 1723 and 1724
affect the flow characteristics of the liquid as it moves through
the chamber 1722. Thus, it is preferable to have surfaces 1723 and
1724 curved and configured to avoid, or minimize, the formation of
any vortices and stagnation zones that would be contacted by, or
interact with, the laser beam as it travels through the liquid into
the nozzle. Preferably, sharper corners on surfaces 1724, 1723
should be avoided. It is also preferable to configure face 1725 and
surfaces 1723 and 1724 to provide the higher flow rates, and avoid
stagnation zones, at the face 1725 of the prism 1705. This enables
the laser beam to be at a higher power density at face 1725,
without overheating, or damaging the liquid or the face 1725.
[0205] To the extent that thermal lensing issues may arise (thermal
lensing in general is a phenomena where the index of refraction of
a fluid, in this case the liquid, changes as its temperature
changes, and thus changes the laser beam) they may be dealt with by
making the internal surfaces of the chamber 1722 and the nozzle
1712 from highly reflective materials. In some instances these
thermal lensing effects are desirable in that they enable the
nozzle to more readily combine the laser beam and the fluid
jet.
[0206] The laser beam 1740 is focused by optics not shown. The
laser beam has a focal point 1741 along the beam path 1716.
Preferably the focal point 1741 may be located within the second
section of the nozzle 1731, or within the third section of the
nozzle 1732.
[0207] The focal point, laser beam properties, laser beam power
density at locations along the beam path, the configuration of the
chamber 1722, the characteristics of the liquid, the flow rates and
pressures of the liquid in operation, and other facts, such as the
operating environmental conditions, should be considered and
balanced in configuring this laser head. Thus, by way of example,
for a 20 kW laser beam, being delivered to the laser tool from an
optical fiber having a core diameter of about 400 to 1000 microns,
for use in a borehole contain drilling mud at a pressure of 10,000
psi, the prism may be made from fused silica, Infrasil, Suprasil,
sapphire, ZnS (Zinc Sulfide) and have an index of refraction of
1.45 for Suprasil, the angle of face 1725 with respect to face 1726
may be 45 degrees, the liquid may be a silicon oil having for
example the properties as follows: viscosity at 25 C, cSt. from
about 10 to 500; viscosity at 99 C, cSt. from about <5 to about
35; viscosity temperature coeff. from about 0.78 to 0.88; index of
refraction from about 1.490 to 1.588; and molecular weights from
about 350-2700. Commercially available silicon oils may be obtained
from, for example Gelest, Inc., and would include PDM-1992, -5021,
-0011, -0021, -0025, -5053, -7040, -7050.
[0208] Turning to FIG. 18, there is shown a general schematic of an
embodiment of a gas jet laser tool. Thus, the laser tool 5601
having a housing 5602. The housing 5602 has a attachment structure
5603 for attaching to a conveyance structure (not shown) and an
attachment structure 5604 for receiving a high power connector 5605
(or other structure for providing the high power laser beam). The
connector has a back reflection protection annular cap 5606. Within
the housing 5602 of the laser tool 5601 there is an optics assembly
5607. The optics assembly 5607 has a collimating lens 5608 and a
focusing lens 5609. The components of the optics assembly, 5608,
5609 may be mounted to the housing 5602, by way of a mountings (not
shown) that have openings or ports for permitting the gas flow to
pass. The optics assembly 5607 may be contained within a housing
5608, which protects the optics and has a window 5609 and an
opening 5610 for receiving the high power laser beam or the
connector 5605.
[0209] The laser tool 5601 has a mirror 5611 that has a mount 5612.
The mirror is reflective to the wavelength of the laser and
transmissive to other wavelengths. Preferably, the mount 5612 does
not have ports or openings to permit gas flow. A photoreceptor 5613
is located behind the mirror 5611 and in the line of sight through
the mirror 5611 to the nozzle 5614. In this embodiment, the nozzle
5614 that extends beyond the body of the laser tool 5601.
[0210] The photoreceptor receives light that enters the nozzle 5614
and travels through the mirror 5611. The photoreceptor may transmit
data, information or the received light to the surface or other
location for the purpose of monitoring, observing, controlling, or
analyzing the cutting process or the tool. The photoreceptor may be
place on the housing 5602, so that it may receive light without it
having to pass through the nozzle and the mirror. In this way, the
photoreceptor may monitor back reflections, or the absence of such
reflections, from the work piece. Back reflections from the work
piece may also be monitored through the mirror, provided that the
mirror is sufficiently reflective of the wavelength to reflect the
vast majority of the laser beam, and that the photoreceptor is able
to detect the small amount of light at the laser beam wavelength
that passed through the mirror.
[0211] In operation gas is flowed through the housing 5602 and out
the nozzle 5614 to form a gas jet 5615. The laser beam 5617 is
launched, e.g., propagated, from the connector 5606 into the
components of the optics assembly 5607. The laser beam 5617 has a
focal point 5618 that is removed from the tool, and may be several
inches from the nozzle.
[0212] If the laser beam had a wavelength of 1070 nm and the
optical fiber (not shown) in the connector 5605 has a core size of
600 .mu.m the collimating lens 5608 may be a 150 mm lens and the
focusing lens 5609 may be a 250 mm to a 1500 mm lens. The focal
length may be adjustable (including downhole during cutting
operations), fixed, fixedly adjustable (e.g., it can be changed and
set in the field, but can not be change during cutting operations)
and combinations and variations of these. In using the tool,
preferably the tool is positioned a distance from the work surface
(or vice versa) so that the focal point and the depth of field are
located behind the surface of the work piece. For a complex work
piece, such as for example, a cased borehole having cement behind
the casing, the focal point and depth of field may preferably be
located completely behind the casing, i.e., in the cement.
[0213] Referring now to FIGS. 19 and 19A there is provided a
general schematic for an embodiment of a laser cutting head, which
may be used with a laser fluid jet tool. The figures the embodiment
is configured for use with a gas jet. Thus, there is a laser tool
5700 in a cased borehole 5701, having a sidewall 5702. The tool has
a connection device 5703 for connecting the tool 5700 to a laser
cutting head 5704. The laser cutting head has a mirror 5705, which
may also be a focusing optic, and a nozzle 5706. The laser head
5704 is sized to fill substantially all of the boreholes diameter;
and thus, position and maintain the nozzle in close relationship to
the borehole sidewall 5702.
[0214] Turning to FIG. 19A, which is transverse cross sectional
view along line A-A, of FIG. 19, the shape and position of laser
head 5704 is seen with respect to the borehole sidewall 5702. The
laser head is essentially triangular, with its base 5720 being
arcuate, and its sides 5721, 5722 narrowing to the location of the
nozzle 5706. The base 5720 has pads 5723, 5724, 5725 for engagement
with the borehole sidewall 5702. In operation when the gas jet is
shot from the nozzle, the reactive force will push the laser head
5704 back, such that pads 5723, 5724, and 5725 engage the borehole
sidewall 5702. The laser beam would them be fired and the tool and
the laser head rotated, or otherwise moved, to deliver a laser beam
pattern to the sidewall. Openings 5740 , 5741 are provided in the
laser head 5704, if circulation was desired during the laser
cutting operations.
[0215] In situations where it may be desirable to perform a
radially limited complete cut, for example removal of an inner
string of casing, while not cutting an outer string of cases, which
outer string is cemented to the formation. If the casing is filled
with brine or water, a wavelength for the laser may be selected
such that the brine or water present has heavy absorption
characteristics. In this manner the laser brine and water would
attenuate the laser. The jet pressure may then be selected, in view
of the attenuation, and other cutting conditions, e.g., pressure,
to limit, or predetermine, the length of the jets travel into the
casings to be cut, e.g., the reach of the jet from the tool is
controlled and predetermined. The laser beam would then be
dispersed at this predetermine location by the water or brine, in
such a manner where the inner casing is completely severed and the
outer casing is not cut or otherwise adversely effected by the
laser beam. In this embodiment, it is preferable to have a
centralizing device, or other apparatus to know the location of the
tool within the casing and thus, have a reference point for
determining the reach of the jet.
[0216] Optics and Optical Components
[0217] By way of example, the types of laser beams and sources for
providing a high power laser beam may, by way of example, be the
devices, systems, and beam shaping and delivery optics that are
disclosed and taught in the following US Patent Applications and US
Patent Application Publications: Publication No. US 2010/0044106,
Publication No. US 2010/0044105, Publication No. US 2010/0044103,
Publication No. US 2010/0044102, Publication No. US 2010/0215326,
Publication No. 2012/0020631, Ser. No. 13/210,581; Ser. No.
13/403,132; Ser. No. 13/403,509; Ser. No. 13/486,795; and Ser. No.
61/493,174, the entire disclosures of each of which are
incorporated herein by reference. The source for providing
rotational movement, for example may be a string of drill pipe
rotated by a top drive or rotary table, a down hole mud motor, a
down hole turbine, a down hole electric motor, and, in particular,
may be the systems and devices disclosed in the following US Patent
Applications and US Patent Application Publications: Publication
No. US 2010/0044106, Publication No. US 2010/0044104, Publication
No. US 2010/0044103, Ser. No. 12/896,021, Ser. No. 61/446,042; Ser.
No. 13/403,509; 13/403,287; and Ser. No. 13/211,729, the entire
disclosures of each of which are incorporated herein by
reference.
[0218] High Power Laser Cables, Umbilicals & Deployment
Systems
[0219] By way of example, umbilicals, high powered optical cables,
and deployment and retrieval systems for umbilical and cables, such
as spools, optical slip rings, creels, and reels, as well as,
related systems for deployment, use and retrieval, are disclosed
and taught in the following US Patent Applications and Patent
Application Publications: Publication No. 2010/0044104; Publication
No. 2010/0044106; Publication No. 2010/0044103; Publication No.
2010/0215326; Publication No. 2012/0020631; Publication No.
2012/0074110; Ser. No. 61/605,401; Ser. No. 13/403,692; Ser. No.
13/403,723; and, Ser. No. 13/437,445, the entire disclosure of each
of which is incorporated herein by reference, and which may
preferably be used as in conjunction with, or as a part of, the
present tools, devices, systems and methods and for laser removal
of an offshore or other structure. Thus, the laser cable may be: a
single high power optical fiber; it may be a single high power
optical fiber that has shielding; it may be a single high power
optical fiber that has multiple layers of shielding; it may have
two, three or more high power optical fibers that are surrounded by
a single protective layer, and each fiber may additionally have its
own protective layer; it may contain other conduits such as a
conduit to carry materials to assist a laser cutter, for example
oxygen; it may have conduits for the return of cut or waste
materials; it may have other optical or metal fiber for the
transmission of data and control information and signals; it may be
any of the combinations set forth in the forgoing patents and
combinations thereof.
[0220] In general, the optical cable, e.g., structure for
transmitting high power laser energy from the system to a location
where high power laser activity is to be performed by a high power
laser tool, may, and preferably in some applications does, also
serve as a conveyance device for the high power laser tool. The
optical cable, e.g., conveyance device can range from a single
optical fiber to a complex arrangement of fibers, support cables,
armoring, shielding on other structures, depending upon such
factors as the environmental conditions of use, tool requirements,
tool function(s), power requirements, information and data
gathering and transmitting requirements, etc.
[0221] Generally, the optical cable may be any type of line
structure that has a high power optical fiber associated with it.
As used herein the term line structure should be given its broadest
construction, unless specifically stated otherwise, and would
include without limitation, wireline, coiled tubing, logging cable,
umbilical, cable structures used for completion, workover,
drilling, seismic, sensing logging and subsea completion and other
subsea activities, scale removal, wax removal, pipe cleaning,
casing cleaning, cleaning of other tubulars, cables used for ROV
control power and data transmission, lines structures made from
steel, wire and composite materials such as carbon fiber, wire and
mesh, line structures used for monitoring and evaluating pipeline
and boreholes, and would include without limitation such structures
as Power & Data Composite Coiled Tubing (PDT-COIL) and
structures such as Smart Pipe.RTM.. The optical fiber
configurations can be used in conjunction with, in association
with, or as part of a line structure.
[0222] Generally, these optical cables may be very light. For
example an optical fiber with a Teflon shield may weigh about 2/3
lb per 1000 ft, an optical fiber in a metal tube may weight about 2
lbs per 1000 ft, and other similar, yet more robust configurations
may way as little as about 5 lbs or less, about 10 lbs or less, and
about 100 lbs or less per 1,000 ft. Should weight not be a factor,
and for very harsh, demanding and difficult uses or applications,
the optical cables could weight substantially more.
[0223] By way of example, the conveyance device or umbilical for
the laser tools transmits or conveys the laser energy and other
materials that are needed to perform the operations. It may also be
used to handle any waste or returns, by for example having a
passage, conduit, or tube incorporated therein or associated
therewith, for carrying or transporting the waste or returns to a
predetermined location, such as for example to the surface, to a
location within the structure, tubular or borehole, to a holding
tank on the surface, to a system for further processing, and
combinations and variations of these. Although shown as a single
cable multiple cables could be used. Thus, for example, in the case
of a laser tool employing a compound fluid laser jet the conveyance
device could include a high power optical fiber, a first line for
the core jet fluid and a second line for the annular jet fluid.
These lines could be combined into a single cable or they may be
kept separate. Additionally, for example, if a laser cutter
employing an oxygen jet is utilized, the cutter would need a high
power optical fiber and an oxygen, air or nitrogen line. These
lines could be combined into a single tether or they may be kept
separate as multiple tethers. The lines and optical fibers should
be covered in flexible protective coverings or outer sheaths to
protect them from fluids, the work environment, and the movement of
the laser tool to a specific work location, for example through a
pipeline or down an oil, gas or geothermal well, while at the same
time remaining flexible enough to accommodate turns, bends, or
other structures and configurations that may be encountered during
such travel.
[0224] By way of example, one or more high power optical fibers, as
well as, lower power optical fibers may be used or contained in a
single cable that connects the tool to the laser system, this
connecting cable could also be referred to herein as a tether, an
umbilical, wire line, or a line structure. The optical fibers may
be very thin on the order of hundreds e.g., about greater than 100,
of .mu.m (microns). These high power optical fibers have the
capability to transmit high power laser energy having many kW of
power (e.g., 5 kW, 10 kW, 20 kW, 50 kW or more) over many thousands
of feet. The high power optical fiber further provides the ability,
in a single fiber, although multiple fibers may also be employed,
to convey high power laser energy to the tool, convey control
signals to the tool, and convey back from the tool control
information and data (including video data) and cut verification,
e.g., that the cut is complete. In this manner the high power
optical fiber has the ability to perform, in a single very thin,
less than for example 1000 .mu.m diameter fiber, the functions of
transmitting high power laser energy for activities to the tool,
transmitting and receiving control information with the tool and
transmitting from the tool data and other information (data could
also be transmitted down the optical cable to the tool). As used
herein the term "control information" is to be given its broadest
meaning possible and would include all types of communication to
and from the laser tool, system or equipment.
[0225] Generally, it is preferred that when cutting and removing
large structures, such as, e.g., multi-string caissons, jackets,
piles, and multi-string conductors, requires that after the cut is
performed, that the completeness of cut be verified before a heavy
lift ship is positioned and attached for the lift, e.g., hooked up,
to remove the sectioned portion. If the cut is not complete, and
thus, the sectioned portion is still attached to the rest of the
structure, the lift ship will not be able to lift and remove the
sectioned portion from the structure. Heavy lifting vessels, e.g.,
heavy lift ships, can have day rates of hundreds-of-thousands of
dollars. Thus, if a cut is not complete, the heavy lift ship will
have to be unhooked and kept on station while the cutting tool is
repositioned to complete the cut and then the heavy lift ship is
moved back in and re-hooked up to remove the sectioned portion.
During the addition time period for unhooking, completing the cut
and re-hooking, the high day rate is being incurred. Additionally,
there are safety issues that may arise if a lift cannot be made
because of an incomplete cut. Therefore, with a laser cut, as well
as with conventional cutting technology it is important to verify
the completeness of the cut. Preferably, this verification can be
done passively, e.g., not requiring a mechanical probing, or a test
lift. More preferably the passive verification is done in
real-time, as the cut is being made.
[0226] In the laser cutting process, a high power laser beam is
directed at and through the material to be cut with a high pressure
fluid, e.g., gas, jet for, among other things, clearing debris from
the laser beam path. The laser beam may generally be propagated by
a long focal length optical system, with the focus either midway
through the material or structure to be cut, or at the exit of the
outer surface of that material or structure. When the focus is
located midway through the material or structure, there is a waist
in the hole that the laser forms in that material or structure,
which replicates the focal point of the laser. This waist may make
it difficult to observe the cut beyond this point because the waist
can be quite small. The waist may also be located in addition to
midway through, at other positions or points along the cut line, or
cut through the material.
[0227] A laser radar system using a near diffraction limited diode
laser source or q-switched laser can be aligned to be co-linear
with the high energy laser beam and it can be used to probe the cut
zone and provide passive, real-time monitoring and cut
verification. A near-diffraction limited sourced for the laser
radar system is preferred, but not essential, because it can create
a laser beam that is significantly smaller in diameter than the
high power laser beam and as a consequence can probe the entire
length of the cut without interference. Although the laser radar
laser beam is preferably coaxial with the cutting laser beam, it
may also be scanned or delivered on a separate beam path. The laser
radar laser beam may also be bigger in diameter than the high
energy laser beam to, for example, image the entire cut. The signal
that is reflected from the cut zone is analyzed with a
multi-channel analyzer, which tracks how many hits are obtained at
a specific range and velocity. Any signal returns that indicate a
near zero velocity, or a velocity consistent with the penetration
rate of the high power laser, will be either the grout or steel
surface to be cut. High velocity returns will correspond to the
debris being stirred up by the high pressure jet and negative
velocities will be the inflow of fluid from the penetration
zone.
[0228] The laser radar will have a laser source, a very narrowband
filter, a high speed pulse power supply, a high speed detector, a
timer, a counter and a multi-channel analyzer system. A
multi-channel analyzer system is not essential, but is preferred
and provides a convenient means to sort the data into useful
information. The laser radar can be a laser source that is a
significantly different wavelength than the high power laser
ranging from the visible to the infrared wavelengths. As long as
the radar laser wavelength is sufficiently outside of the high
power laser spectrum band, then the laser radar signal can be
isolated with a high quality narrow band-pass filter of 1 nm in
width or less. If a laser diode is used as the source, the laser
diode will be stabilized in wavelength by an external grating,
etalon or dispersive element in the cavity. Bragg Gratings have
shown that ability to stabilize a laser diode to 1 pico-meter,
significantly more stable than needed for this application.
[0229] The laser radar can operate in, for example, two modes: 1)
time of flight and 2) phase delay in a pseudo-random continuous
modulation format. The laser radar can determine the velocity of
the return using, for example, one of two methods: 1) the
difference between two consecutive distance measurements divided by
the time delay between the two measurements, or 2) a Doppler
frequency shift caused by the particle moving either away or toward
the observer. The post processing of the raw data can be used to
determine if the laser radar is measuring the advancement of the
laser cutting zone, the inflow of external mud or the outflow of
debris and gas.
[0230] The laser radar could also be employed in a liquid jet based
design. However, the time of flight is now a strong function of the
refractive index of the fluid, which changes with pressure and
temperature. Therefore, these characteristics of the liquid media
being used during the cutting process should be understood and
addressed in the design of the laser radar system for a liquid
laser jet cut.
[0231] It may also be possible to use cameras and spectrometers to
image the exit of the cut once the laser has penetrated the outer
casing. Similarly, X-ray Fluorescence, eddy current detectors,
Optical Coherence Tomography, and ultra sound as potential
solutions, may also be used for real-time and real-time passive cut
verification, however, for these approaches the solid angle
represents a more significant issue than for the laser radar
system, making that system preferable. Further, these systems are,
or may be, more complex than the laser radar system, which may make
them more difficult to integrate and harden for down-hole
deployment and use.
[0232] Although not specifically shown in the embodiment of the
figures and examples, break detection and back reflection monitory
devices and systems may be utilized with, or integrated into the
present tools, umbilicals, optical cables, deployment and retrieval
systems and combinations and variation so these. Examples of such
break detection and monitoring devices, systems and methods are
taught and disclosed in the following US Patent Application: Ser.
No. 13/486,795, Publication No. 2012/00074110; Ser. No. 61/446,407;
and Ser. No. 13/403,723, and U.S. Pat. No. Application Publication
No. 2010/0044106, the entire disclosures of each of which are
incorporated herein by reference.
[0233] By way of example, the flexible support cables for the laser
cutters, heads and tools provide the laser energy and other
materials that are needed to perform the cutting operation.
Although shown as a single cable for each laser cutter, multiple
cables could be used. Thus, for example, in the case of a laser
cutter employing a compound fluid laser jet the flexible support
cable would include a high power optical fiber, a first line for
the core jet fluid and a second line for the annular jet fluid.
These lines could be combined into a single cable or they may be
kept separate. Additionally, for example, if a laser cutter
employing a nitrogen jet is utilized, the cutter would need a high
power optical fiber and a nitrogen line. These lines could be
combined into a single cable or they may be kept separate as
multiple cables. The lines and optical fibers should be covered in
flexible protective coverings or outer sheaths to protect them from
riser fluids, the subsea environment, and the movement of the laser
cutters, while at the same time remaining flexible enough to
accommodate the orbital movement of the laser cutters. As the
support cables near the feed-through assembly their flexibility may
decrease and more rigid means to protect them can be employed. For
example, the optical fiber may be placed in a metal tube. The
conduit that leaves the feet through assembly adds additional
protection to the support cables, during assembly of the laser
module and the riser, handling of the riser or module, deployment
of the riser, and from the subsea environmental conditions.
[0234] High Power Lasers
[0235] By way of example, the laser systems of the present
invention may utilize a single high power laser, or they may have
two or three high power lasers, or more. High power solid-state
lasers, specifically semiconductor lasers and fiber lasers are
preferred, because of their short start up time and essentially
instant-on capabilities. The high power lasers for example may be
fiber lasers or semiconductor lasers having 5 kW, 10 kW, 20 kW, 50
kW or more power and, which emit laser beams with wavelengths in
the range from about 455 nm (nanometers) to about 2100 nm,
preferably in the range about 800 nm to about 1600 nm, about 1060
nm to 1080 nm, 1530 nm to 1600 nm, 1800 nm to 2100 nm, and more
preferably about 1064 nm, about 1070-1083 nm, about 1360 nm, about
1455 nm, 1490 nm, or about 1550 nm, or about 1900 nm (wavelengths
in the range of 1900 nm may be provided by Thulium lasers). Thus,
by way of example, the present tools, systems and procedures may be
utilized in a system that is contemplated to use four, five, or
six, 20 kW lasers to provide a laser beam in a laser tool assembly
having a power greater than about 60 kW, greater than about 70 kW,
greater than about 80 kW, greater than about 90 kW and greater than
about 100 kW. One laser may also be envisioned to provide these
higher laser powers. Examples of preferred lasers, and in
particular solid-state lasers, such as fibers lasers, are disclosed
and taught in the following US Patent Applications and US Patent
Application Publications Publication No. US 2010/0044106,
Publication No. US 2010/0044105, Publication No. US 2010/0044103,
Publication No. US 2010/0044102, Publication No. US 2010/0215326,
Publication No. 2012/0020631, Ser. No. 13/210,581, and Ser. No.
61/493,174, the entire disclosures of each of which are
incorporated herein by reference. Additionally, a self-contained
battery operated laser system may be used. This system may further
have its own compressed gas tanks, and be submergible, and may also
be a part of, associated with, or incorporation with, an ROV, or
other sub-sea tethered or free operating device.
EXAMPLES
[0236] The following examples are provide to illustrate various
devices, tools, configurations and activities that may be performed
using the high power laser tools, devices and system of the present
inventions. These example are for illustrative purposes, and should
not be view as, and do not otherwise limit the scope of the present
inventions.
Example 1
[0237] Biologic growth on a subsea structure can add considerable
weight to that structure making it more difficult and costly to
remove. Thus, a high power pulsed laser may be used to remove such
biological growth from the structure before it is cut, or before it
is lifted above the surface of the water. For example, a laser tool
may be moved along the members of the structure by for example an
ROV, or the laser tool may be positioned just below the surface of
the water so that the biological material can be removed as the
member is lifted from the water. In this manner, the hoisting
device will have buoyancy of the water to assist in the lifting of
the member below the surface of the body of water (which could a
considerable distance) but not be burdened with this extra weight
when as the member is removed from the water. Additionally, the
cleaning of the sub-sea removed objects in many cases is a
regulatory requirement. For example, in the California, there may
be a requirement to utilize divers with high pressure washer to
clean the legs to .about.100 feet, with the remainder of the
removed components cleaned above water before disposal. Using a
laser system provides the ability to clean the structure top to
bottom, complying with all requirements, providing an enhanced
environmentally safe removal, as well as, potentially lessening the
weight which in turn provides for the use of scaled down or smaller
surface equipment. Additionally, the laser cleaning of structures
may be used for structures, vessels, and equipment in active use
not scheduled or intended to be removed or decommissioned. And, may
do so in a manner that does not appreciably weaken, or adversely
effect the underlying metal, or other structural materials being
cleaned.
[0238] For example, a typical pulsed laser may be a semiconductor
laser or a fiber laser operating in a pulsed mode. A typical pulse
characteristic, for example, may be a 5 kHz modulation rate with a
10%-50% duty cycle.
Example 2
[0239] In this example, there is provided a method of cutting
through a conductor having multiple tubulars and annular areas.
Thus, turning to FIG. 11 there is shown a configuration of tubulars
1101, having a conductor 1102, a first annulus 1105, an inner
casing 1103, a second annulus 1106 and an internal casing 1104. The
annuli 1105, 1106 may be open space, contain cement, a drilling
fluid, or combinations and variations of these. The laser cutting
tool 1107, has a gas jet laser cutting head of the type for example
of the embodiment shown in FIG. 12, which directs a laser beam and
gas jet along path 1108. The internal casing 1104 is cut using two,
three, four or more passes of the laser to create an area of
removed material 1104a. (Only the beginning of the cuts are shown
in FIG. 11, it being understood that each of these cuts would
preferably extend around the circumference of the casing and thus
the removed material would be a ring) The inner casing 1103 is cut
using fewer passes of the laser to create a smaller area of removal
1103a. The conductor is then cut using fewer passes, or preferably
a single pass, to create a smaller area of removal 1102a. In this
manner, the surface effects, which may be detrimental to the
integrity of the jet, that are caused by the edges of the tubular
boarding an area of removal will be avoided, because each
successive tubular has a narrow cut. This stepped method of cutting
may preferably be utilized for a gas jet when the annular areas are
open space, and may also be utilized when the annular areas are
filled, e.g., contain other materials, such as cement.
Example 3
[0240] In this example a laser removal system may be used to assist
in the plugging abandonment and decommission of a subsea field. The
field is associated with a floating spar platform. Two mobile
containers are transported to the spar platform, containing a laser
module, and a work container have laser cutting tools, devices,
umbilicals and other support materials. The laser module obtains
its power from the spar platform's power generators or supplied
power generation. The laser cutting tools are lowered by the spars
hoisting equipment, to the seafloor, where they are lowered into a
first well that has been plugged, the laser tool directs a high
power laser beam, having about 10 kW of power, in an air jet,
around the interior of the well. The laser beam and jet in a single
pass severs all of the tubulars in the well at about 15 feet below
the mud line. This process is repeated for the remaining wells in
the field that are to be abandoned.
Example 4
[0241] In this example a laser system may be used to repair
conductors in an offshore platform. The platform is a fixed
jacket-pile type structure located in 500 feet of water. The
platform has 50 conductors extending from the platform deck to, and
into the seafloor. 20 of those conductors are damaged by a storm.
The laser cutting tool is positioned around the exterior of each
conductor and the damaged sections is cut and removed. In may be
severed and pulled, or may be severed at the top and bottom and
axially cut (e.g., split along its side). The angle of the beam
path may be such that a predetermined edge is made on the end of
the remaining connector section to facilitate the placement and
securing of a new section of connector. The high power laser may
also be used to weld these sections in place.
Example 5
[0242] A laser removal system may be used to recover 15,000 feet of
31/2'' and 41/2'' tubing from a total of six wells. The laser
removal system is used in conjunction with and interfaces with the
existing platform and hoisting equipment. As the tubing is pulled
it is quickly cut in to lengths of 30 to 35 feet, by a laser
cutting device on the platform's floor. This avoids the use and
associated cost of a separate rig and could allow for the reuse of
tubulars in future projects.
Example 6
[0243] A laser decommissioning vessel may be used to remove a
subsea 30'' multi-string casing stub that is covered with debris
(sand bags) and is wedged and bent against an operating pipeline
and is located at a depth of 350 feet. The inner casing string,
133/4'', in the multi-string stub is jammed with an unknown
material starting at about 1 foot below the sea floor that could
not be removed by jetting. All strings of casing in the
multi-string stub are fully cemented. A laser removal system and
tool is used to remove this stub without the need for dredging. A
laser tool having two beam paths, a boring beam path and a severing
beam path, is used to first bore through the jammed material in the
inner casing string. This provides access for the tool down to 18
feet below the sea floor. The tool then severs the multi-string
stub in 3-foot sections, until the stub is removed to 15 feet below
the sea floor. The smaller, 3 foot sections are used to accommodate
the use of a smaller and less expensive hoisting equipment.
Additionally, because the structural integrity of the stub is
unknown multiple smaller sections are lifted instead of a single
15-foot section.
Example 7
[0244] A laser decommissioning vessel may be used to assist in the
removal of a jacket and deck platform structure in 130 feet of
water, having four vertical support members. Two of the vertical
support members are large diameter caisson legs, which functioned
as floatation devices for transport of the jacket to the offshore
location. The other two vertical support members have smaller
caisson at their base. Piles are driven through sleeves in all four
caissons anchoring the structure to the sea floor. Horizontal and
tie members are also present between the vertical support members.
After the decks are removed, and while the structure is being
supported by a crane, a laser cutting tool is lowered into a large
casing and the casing is cut at a predetermined point using an
inside-to-outside laser cutting method. This step is then repeated
for the other large casing. The smaller vertical members are then
cut using a tool for example of the type shown in the embodiment of
FIG. 7 and with an outside-to-inside laser cut. Any interfering tie
or horizontal members are also cut. The section is then lifted from
the sea and placed on the deck of the decommissioning vessel. The
removed section is then cut into smaller sections and feed into the
laser shop where is it reduced to sections that are no more than 4
feet in length. In the laser shop, or before lifting from the sea,
biologic growth may also be removed. This process is repeated until
the entire structure above the sea floor is removed, and reduced to
4-foot sections of clean scrap. (Depending upon the capabilities of
and price being offered by scrap dealers different lengths of the
scrap may be utilized) The earth around the piles is then dredge to
a depth of 6 feet and the piles are severed at 5 feet below the sea
floor using the tool of FIG. 7.
Example 8
[0245] A laser removal system may be used to remove support cables
and pipelines that are positioned along the sea floor from the
shoreline to an offshore platform. These support structures could
include electrical lines, water lines and lines for transporting
hydrocarbons to shore. Because of the rapid and reliable manner in
which the laser cutting tools can cut these structures, they can be
cut into smaller sections that are more readily, easily and
economically removed from the sea floor.
Example 9
[0246] A heavy lifting vessel having for example a crane with a
lifting capacity in excess of 500 tons is stationed by a fixed
platform in 1,000 feet of water. The heavy lifting vessel is used
to remove the deck and top structures of the platform. Upon removal
of these structures the heavy lifting vessel is no longer needed
and leaves the site. As the heavy lifting vessel leaves the site, a
smaller laser cutting system is stationed at the site. The laser
cutting system provides the ability to make safe, easy,
predetermined cuts, and thus to cut the jacket into small,
manageable pieces, which can be removed without the need for the
heavy lifting vessel. In this manner the laser removal system and
method allows for systematic removal of the jacket in smaller,
easily handled pieced, starting from the top, and moving down.
Example 10
[0247] Turning to FIG. 21, there is shown a schematic of an example
of a monopile structure and associated foundation with a laser
decommissioning vessel and a support vessel on station. Thus, the
monopole has a tower 2102, having a work platform 2101, an
intermediate platform 2106 and a boat landing 2107 are above the
surface 2105 of a body of water 2121. The tower 2102 extends over a
monopile 2111, which extends through a scour protection member
2110, into and below the seabed 2112. Thus, the tower 2102 extends
from within the body of water 2121 to above the surface 2105 of the
body of water 2121. The structure may be viewed as having several
sections or areas: a substructure area shown by arrow 2113, a
foundation area shown by arrow 2112, and a transition area 2114.
There is also a grout area 2109 where the tower 2102 is grouted to
the monopile 2111. The structure also has an external J tube 2108.
Although one support vessel 2103 and one laser decommission vessel
2104 are shown, it should be understood that they may be a single
vessel or other vessels or types of vessels, in addition to the two
that are shown in the figure. The wells are first plugged as
required by regulations for the particular area. The conductors,
production pipe and other tubulars within the monopile 2111 and
tower 2102 are cut with a laser tool. For example the laser tool of
the embodiment of FIG. 34 would cut the conductors internal to
external at 15 feet below the mudline. Following the removal of the
all internal and external components of the monopile, the topside
of the work platform 2101, and the tower 2102, down to below the
subsea transition 2114 would be removed via a laser tool of for
example the embodiment of FIG. 18 or FIG. 30. The upper section now
being removed allows for clear diver access to remove the subsea
internal centralizer (not shown) as well as clear access to have
the mud plug jetted from the pile down to 15 to 20 feet below the
seafloor. Upon clear access down to 15 feet below the seafloor a
laser tool of the embodiment of FIG. 18 or FIG. 30 would cut the
monopile internal to external. Outside in laser cutting may also be
performed, for example if obstructions prevented a tool from
accessing the monopile internally and it was determined for some
reason that this obstruction would not be removed with a
differently configured laser tool, for example having a forward
propagating beam path as shown in the embodiment of FIG. 3. For the
internal cut a fluid, and preferable one that is transmissive to,
or substantially transmissive to the laser, such as water, salt
water, mineral oil, or diesel, may be jetted and pumped from the
inside of the monopile to a sufficient amount, level to provide
access to the intended laser cut area. For the external cut the
material around the monopile may be dredge out to provide access
for the laser cutting tool, or a tool that is capable of being
forced through the mud may be used. The transition section may also
be cut with the laser tool and removed in one or more sections, or
if the transition piece is grouted or otherwise affixed to the
monopile the assembly may be removed with one lift. One of the
advantages of the laser plugging and abandonment procedure is the
ability to have predetermined and precise and efficient sectioning
of large sections of these structures to smaller more easily, and
cost effectively, handled sections.
Example 11
[0248] Turning to FIG. 22, there is shown a schematic of an example
of a tripod structure and associated foundation with a laser
decommissioning vessel 2204 and a support vessel 2203 on station.
Thus, there is provided a tower 2202 formed from a central column
2250, having a work platform 2201, an intermediate platform 2206,
and a boat landing 2207, which are located above the surface 2205
of a body of water 2221. The central column 2250 has internal j
tubes 2208 associated with it. Below the surface 2205 there are
emerging internal j tubes 2230, diagonal braces, e.g., 2231, pile
sleeve, e.g., 2232, and piles, e.g., 2234. The piles 2234 may be
for example piles that are mechanically driven into the seabed 2222
or they may be suction caissons. Only two of three pile and sleeves
are shown in the Figure. The piles 2234 are positioned through a
mudmate 2233 and into the seabed 2222. The structure may also be
viewed as having sections or areas: a substructure as shown by
arrow 2213 and a foundation area as shown by arrow 2212. Although a
support vessel and a laser decommission vessel are shown, it should
be understood that in this and the other examples, unless
specifically stated otherwise, that these vessels may be a single
vessel or other vessels in addition to those shown in the figure
may be used and that these vessels in the figures of the examples,
are only illustrative and thus the vessels may have other shapes,
configurations, lifting devices, no lifting devices, and
capabilities, etc. The wells are first plugged as required by
regulations for the particular area. The conductors, production
pipe and other tubulars within the tower 2202 are cut with a laser
tool. For example the laser tool of the embodiment of FIG. 34 would
cut the conductors internal to external at 15 feet below the
mudline. Following the removal of the all internal and external
components of the tower, the topside work platform 2101 and tower
2202 would be removed to just above the seabed 2222 via a laser
tool of for example the embodiment of FIG. 29. The upper sectioned
now removed allows for clear diver access to remove the subsea
internal centralizer (not shown). Upon unobstructed access down to
15 feet below the seafloor a laser tool of the embodiment of FIG.
29 would be lowered down the main tower and braced piles. Once at a
point of resistance in each pile, due to mud plug, the tool would
then release the upper anchors 2902 and secure to the interior of
the pile wall, once securely fastened to the pile, the lower
actuator 2903 will activate and drive the tools lower section 2905
down to the cutting depth of 15 feet and actuate the lower laser
rotating arms 2906, 2907, 2908. The laser package can be placed in
one, two or all of the arms for better cut efficiency. Once the
arms have reached the interior pile wall, the lower tool section
2905 will begin to rotate, gas will flow thru the tool, down thru
the arm or arms, thru the nozzle(s) and the laser will be initiated
and rotated until the radial cut is complete. Upon completion of
the cut the tool will be pulled back up to the laser vessel 2204
and the structure will be removed from the seafloor.
[0249] The foundations are cut by an inside out laser cut at 20
feet below the sea floor (mud line). Outside in laser cutting may
also be performed. For the internal cut a fluid, and preferable one
that is transmissive to, or substantially transmissive to the
laser, such as water, mineral oil, or diesel, may be jetted and
pumped from the inside of the piles to a sufficient amount, level,
to provide access to the intended laser cut area. For the external
cut the material around the piles will be dredge out to provide
access for the laser cutting tool. The central column 2250 may also
be cut with the laser tool and removed in one or more sections, or
if grouted or otherwise affixed to the piles the assembly may be
removed with one lift. One of the advantages of the laser plugging
and abandonment procedure is the ability to precise and efficient
section of large sections of these structures to smaller more
easily, and cost effectively, handled sections.
Example 12
[0250] Turning to FIG. 23, there is shown a schematic of an example
of a gravity structure and associated foundation with a laser
decommissioning vessel 2304 and a support vessel 2303 on station.
Thus, there is provided a tower 2302 formed by a shaft 2309, having
a boat landing 2307, an intermediate platform 2306, and a work
platform 2301, positioned above the surface 2305 of a body of
water. These are associated with the shaft 2309 internal J tubes
2308. There is also provided scour protection 2311 and an
under-base grout 2310, that is located below the mudline 2322. The
structure may also be viewed as having sections or areas: a
substructure as shown by arrow 2313 and a foundation area as shown
by arrow 2312.
[0251] In order to decommission the structure and existing internal
and external components, for example, the laser tool of the
embodiment of FIG. 34 would be used to remove the internal
conductors and/or wells, and an external to internal laser cutting
tool would be used to remove the J-tubes just above or below the
seabed. Once the wells and J tubes 2308 are removed, the upper
tower 2302 down to the transition piece just above the scour
protection area 2311 would be removed via an internal to external
laser cutting tool such as for example shown in FIG. 18 or FIG. 30
or if internal obstructions exist, an external to internal cut
could be performed, or the obstruction could be removed with a
laser tool having for example a forward propagating laser beam
path. Due to excessive scour 2311 and under base grouting 2310,
external dredging or seabed excavation may occur to allow for
proper laser tool placement similar to laser tool of shown in FIG.
7. Once cut has been confirmed by laser cutting tool verification
system the support vessel crane would attach to the severed gravity
based structure and remove from the seabed. Although two vessels
are shown, it should be understood that they may be a single vessel
or other vessel in addition to the three that are shown in the
figure. The various section of the shaft, j-tubes, and under ground
base may be laser cut to form specific section or part for lifting
and removal. One of the advantages of the laser plugging and
abandonment procedure is the ability to cut precise and efficient
large sections of these structures into smaller more easily, and
cost effectively, handled sections.
Example 13
[0252] A larger nuclear facility is in the process of being turned
around through a refurbishing process. The laser cutting systems
and tools are used to remotely cut and section various structures
that are in hazardous areas, to provide greater ease for removal of
those sectioned components. The use of laser cutting remotely,
further provides the ability to perform these cuts in contained
environments, utilizing existing containment structures, and to
produce substantially less waste, e.g., cutting dust, etc. that may
come from mechanical cutting processes or equipment, or partial
and/or water jet cutters.
Example 14
[0253] A chemical facility is in the process of being shut down and
removed from its location. The laser cutting systems and tools are
used to remotely cut and section various structures that are in
hazardous areas, to provide greater ease for removal of those
sectioned components. The use of laser cutting remotely, further
provides the ability to perform these cuts in contained
environments, utilizing existing containment structures, and to
produce substantially less waste, e.g., cutting dust, etc. that may
come from mechanical cutting processes or equipment, or partial
and/or water jet cutters.
Example 15
[0254] The laser cutting systems and tools are used to remove a
subsea system, including subsea pipeline end manifolds (PLEMs) and
subsea pipeline end terminals (PLETs), and/or subsea production
equipment, e.g., controls, templates, skids, separators and other
such types of equipment that may be located on the sea floor. Laser
PIGs, of the type disclosed in U.S. patent application Ser. No.
13/366,882 may also be used in this process.
Example 16
[0255] The laser cutting systems and tools are used to cut and
section portions of a platform deck that are located above the
surface of a body of water. The laser cutters may split the deck in
half, or in smaller sections, to provide for lighter sections to be
lifted. These cuts may be either inside, outside in, or
combinations of these depending upon the type of structures, e.g.,
1-beams, tubular members, deck legs to pile tops, etc., that the
deck and above water line structure is made up of.
Example 17
[0256] In FIG. 24 there is provided an embodiment of a laser
cutting tool that may be used to perform laser removal operations,
such as those set forth in Examples 1 to 16 and other removal,
abandonment, decommissioning, repair and refurbishment operations.
Thus there is provided a laser tool having a body 2411, which is
positioned inside of an inner surface 2401 of a tubular, e.g., a
pile, a pile and conductor, a multi-string conductor, and
combinations and variations of these, to be cut. The laser tool
body 2411 has an optic package 2405, that focuses and directs the
laser beam along beam path 2406 to a reflective device, 2407, for
example a TIR reflective prism. The laser beam traveling along the
beam path leaves the reflective device 2407 and travels toward the
target, e.g., the intended area of laser illumination.
[0257] To obtain deep cuts, the beam has a long depth of field, and
thus has a first spot size at 2408, which is in the area of the
inner surface of the tubular 2401, a focus point 2410 which is
removed from the inner surface of tubular 2401 and a second spot
size 2409, which is removed from the focal point 2410. In this
manner the tool, thus configured, would have an effective cut
distance between spots 2408 and 2409, for a predetermined laser
fluence, which is established to meet the material and cutting
speed requirements for the operation.
[0258] The embodiment of this Example 17, would be a completely
on-axis embodiment, i.e., three axis are aligned. Thus, there is an
axis for the tubular to be cut 2402c, an axis for the tool body
2402b, and an axis for the optics package (including the beam path
exiting the optics package) 2402a. In this embodiment, the axes are
substantially co-axial, and preferable co-axial, i.e., on a same
axis as shown in FIG. 24.
[0259] The tool has fixation devices 2404, 2403, which may serve to
anchor, centralize, fix the tool at a predetermined stand-off
distance, and which may also serve as a packer. Any fixation device
known to the art may be used. Preferably, the fixation device will
have the ability to be used across a wide range of tubular inner
diameters.
Example 18
[0260] In FIG. 25, there is provided an embodiment of a laser
cutting tool that may be used to perform laser removal operations,
such as those set forth in Examples 1 to 16 and other removal,
abandonment, decommission, repair and refurbishment operations.
Thus, there is provided a laser tool having a body 2511, which is
positioned inside of an inner surface 2501 of a tubular, e.g., a
pile, a pile and conductor, a multi-string conductor, and
combinations and variations of these, to be cut. The laser tool
body 2511 has an optic package 2505, that focuses and directs the
laser beam along beam path 2506 to a reflective device 2507, for
example a TIR reflective prism. The laser beam traveling along the
beam path leaves the reflective device 2507 and travels toward the
target, e.g., the intended area of laser illumination.
[0261] To obtain deep cuts, the beam has a long depth of field, and
thus, has a first spot size at 2508, which is in the area of the
inner surface of the tubular 2501, a focus point 2510 which is
removed from the inner surface of tubular 2501 and a second spot
size 2509, which is removed from the focal point 2510. In this
manner the tool, thus configured, would have an effective cut
distance between spots 2508 and 2509, for a predetermined laser
fluence, which is established to meet the material and cutting
speed requirements for the operation.
[0262] The embodiment of this Example 18, would be a three off-axis
embodiment, i.e., three axis are not aligned. Thus, there is an
axis for the tubular to be cut 2502c, an axis for the tool body
2502b, and an axis for the optics package (including the beam path
exiting the optics package) 2502a. In this embodiments these three
axis are not co-axial, with each axis, as shown in the Figure,
having a separate position.
[0263] The tool has fixation devices 2504, which may serve to
anchor, and fix the tool at a predetermined stand-off distance, and
which may also serve as a packer. There is also provided a roller,
bumper, or stand-off device 2520, which engages the inner surface
2520. Any fixation device and stand-off device known to the art may
be used. Preferably, the fixation device will have the ability to
be used across a wide range of tubular inner diameters.
Example 19
[0264] In FIG. 26 there is provided an embodiment of a cutting tool
2611 positioned in a tubular structure 2601. The tool 2611 has an
optics package 2605, which provides a collimated laser beam along
beam path 2606 to a reflective device 2607, which may be a TIR
prism. The collimated laser beam then leaves traveling along the
beam path to focusing optic 2617 which focuses the laser beam. This
embodiment may be an on-axis or off-axis configuration.
Example 20
[0265] In FIGS. 27A to 27C, there is provided an embodiment of a
laser cutting head assembly 5801, which may be used in conjunction
with a laser cutting tool or assembly, a motor section, an optics
package or other similar assembly (all not shown in the figure).
The laser cutting head assembly 5801 has a beam path tube 5802 that
has an outer surface 5820, a side wall 5826 and an inner surface
5805. At the distal end (closest to the laser beam source) there is
provided a treaded section 5804 for attachment to a tool, motor
section, or optics package. At the proximal end there is a nozzle
section 5803 that is threaded into the beam path tube 5802. The
nozzle section 5803 has a hollow body 5827, which has a first
cylindrical chamber 5806, a frustro conical chamber 5807, which
connects chamber 5806 to a second conical chamber 5808. The nozzle
section 5803 has an outer surface 5821, which is aligned with outer
surface 5820. There is provided a member 5810, that has a face 5825
that forms an interior surface of the nozzle 5803. Retaining member
5824 fixes the member 5810 to the nozzle 5803. The member 5810 may
be a reflective device, as described herein, or as is otherwise
know to those of skill in the art for reflecting high power laser
beams. It also may be a selectively reflective and selectively
transmissive device, thus providing for certain predetermined
types, e.g., wavelengths, or amounts, e.g. powers of light to pass
through the member to a detection, analysis or monitoring device,
or to be launched into a fiber for transmission to a detection,
analysis or monitoring device. There is provided a nozzle throat
member 5809, which has a nozzle face 5823, and which is held in
place by locking member 5822.
Example 21
[0266] Using a laser head in a laboratory testing apparatus,
similar to the laser head of the embodiment of Example 20 the
following laser complete cuts were made on and in combinations and
configurations of tubulars and materials as illustrated in FIG. 35A
to 35N, and set forth in Table III.
TABLE-US-00003 TABLE III Figure illustrating configuration of
material Stand Nozzle Focal Process Speed Material cut
Configuration Process Off Diameter Length Power CFM PSI IPM Steel
and 35A 10'' .times. 3/8'' Cut Off 1/2'' .425'' 1000 mm 15.8 KW 280
125 5 Cement 20'' .times. 3/8'' Complete from 16'' .times. 3/4'' ID
in Air Fully Grouted Steel and 35B 10'' .times. 3/8'' Cut 4'' 3/4''
0.325 500 mm 15.1 KW 165 125 1 Cement 20'' .times. 3/8'' Diameter
Hole 16'' .times. 3/4'' Through Fully Fully Grouted Grouted in Air
Steel and 35C 10'' .times. 3/8'' Cut Off 1/2'' .425'' 1000 mm 15.8
KW 280 125 5 Cement 20'' .times. 3/8'' Complete from 16'' .times.
34'' ID in Water Fully Grouted Steel and 35D 10'' .times. 3/8'' Cut
2'' 3/4'' .425'' 1000 mm 15.8 KW 280 125 3 Cement 20'' .times.
3/8'' Diameter Hole 16'' .times. 34'' in water No Grout ungrouted
Steel and 35E 61/4'' .times. 3/8'' Cut off 1'''' .270'' 1000 mm
16.2 KW 185 125 6 10'' .times. 3/8'' complete from Cement Grouted
ID in Water Steel 35F 10'' .times. 3/8'' Cut out Dent up to 2''
.270'' 1000 mm 16.2 KW 185 125 10 Diameter From ID in 3 Tube with
Dent Sections Steel 35G 6.5'' Cut from OD .100'' .060'' 250 mm 17.3
KW 14 125 170 Diameter by around part 3/8'' Thick Tube Steel 35H
8.5'' OD .times. Cut from OD .100'' .225'' 500 mm 17.3 KW 120 125
10.5 4.25 ID Tool around part Joint Steel and 35I 24'' .times.
1/2''- Cut from ID .500'' .300'' 1000 mm 18.0 KW 195 125 43 Cement
20'' .times. 1/2''- Under Water Minutes 16'' .times. 1/2''- with
Sealed to .sup. 7'' .times. 3/8'' Center Cut Cemented Between 16''
and 20'' Steel 35J 101/2'' .times. 3/8''- Cut from ID .500'' .300''
1000 mm 18.0 KW 175 125 43 16'' .times. 1/2''- Under Water Minutes
20'' .times. 1/2'' with Sealed to Ungrouted Center Cut Steel 35K
7'' .times. 3/8''- Cut from ID .500'' .300'' 1000 mm 18.0 KW 175
125 Only 59 16'' .times. 1/2''- Under Water seconds 20'' .times.
1/2''- with Sealed 36'' .times. 1'' Center Ungrouted Steel, 35L
1/2'' Steel- Perforation 2'' .500'' .300'' 500 mm 16.5 KW 200 125 5
Cement 21/2'' Cement Diameter and and 3'' Through Hole Sandstone
Sandstone in Air Steel 35M 1'' Casing Optimizes .500'' .750'' 1000
mm 18.5 KW 295 125 10 to 12 Steel Cutting Speed for 1/2'' Diameter
Beam
Example 22
[0267] In FIG. 28 there is provided an embodiment of a
laser-decommissioning tool, which may be used for example to
perform an inside-to-outside cut on a pile. Thus, there is provided
a tool 2801 having a first section 2804 that has associated
therewith anchoring devices 2802, 2803 and a third anchoring device
(not shown). The first section 2804 is hollow and contains the high
power laser fiber, control cables or wires, and passages for
transmitting the laser cutting fluid. The first section is
rotationally coupled to a second section 2805 that contains an
extension mechanism 2807 such as a piston, or mechanical jack, that
moves the laser head arm 2806 into a cutting position. The laser
head arm contains an optics package for focusing and direction the
laser beam and also a nozzle package for forming the laser-fluid
jet. Although one laser head arm is shown in this embodiment, two,
three or more may be used. Thus, in use the laser head arm is in a
retracted position, within the outer cage 2812, as the tool is
lowered into position within the pile. The outer cage 2812 protects
the laser head. Thus, time and equipment costs may be saved, by
avoiding the step of removing, e.g., dredging out the mud that may
otherwise typically be located within the pile at and above the
area to be cut. In this manner the tool may be pushed through the
mud, for example by using coiled tubing and an injector system, to
the position of the cut, e.g., 15 feet below the sea bed. The laser
head arms may then be opened, by forcing them through the mud with
the pistons. The lower section may then be rotated (by internal
motor section not shown) to perform the cut, by moving the laser
head arms through the mud. The shape of the laser head arms may be
such as to more easily move through the mud, such as a partial or
complete diamond shape, e.g., a knife-edge on the leading face for
outward movement, and a knife-edge on the leading face for
rotational movement. It being noted that this tool may also be
advanced to the cut location after any mud or debris has been
removed from the pile or tubular to be severed.
Example 23
[0268] Turning to FIG. 29, there is provided an embodiment of a
laser tool that eliminates the need for dredging the work site
before performing a laser cut. Thus, there is provided a laser tool
2901 having an anchoring section 2902, a pushing or extension
section 2903, a motor section 2904 and a lower rotation section
2905 that in this embodiment has three laser head arms 2906, 2907,
2908. The arms are shown in their retracted positions in the
figure. The anchoring section 2902, the pushing section 2903, and
the motor section 2904 may have passages for the laser fiber, data
and control lines and for conveying any fluids used for the fluid
laser jet. (It should be understood that the optical fibers, data
and control lines, and passages for fluids, e.g., conduit forming
the passage(s) may be located outside of the tool and attached to
or otherwise associated with the laser arm heads 2906, 2907, 2908.
In operation the tool is lowered into the tubular to be cut, unit
sufficient resistant is encounter that it can no longer be advance,
by gravity or by force from for example an injector. At this point
the anchors are set, fixing the tool in position. The pushing
section is the activated and elongates, pushing the motor section
2904 and the rotating section 2905 down into the mud to the
location where the cut is to be performed. Extending device then
move the laser head arms 2906, 2907, 2908 out to engage, or be
adjacent to, near to, or within reach of the laser jet under the
particular mud conditions and environment, the inner surface of the
tubular. The laser head arms 2906, 2907, 2908 each contain an
optics package for focusing and direction the laser beam and also a
nozzle assembly for forming the laser-fluid jet. Thus, time and
equipment costs may be saved, by avoiding the step of removing,
e.g., dredging out the mud that may otherwise typically be located
within the tubular at and above the area to be cut. In this manner
the tool may be pushed through the mud to the position of the cut,
e.g., 15-20 feet below the sea bed. The laser head arms may then be
opened, by forcing them through the mud with the pistons. The lower
section 2905 may then be rotated by motor section 2904 to perform
the cut, by moving the laser head arms through the mud. The shape
of the laser head arms may be such as to more easily move through
the mud, such as a partial or complete diamond shape, e.g., a
knife-edge on the leading face for outward movement, and a
knife-edge on the leading face for rotational movement. It being
noted that this tool may also be advanced to the cut location after
any mud or debris has been removed from the tubular to be
severed.
Example 24
[0269] Turning to FIG. 30 there is provided a laser tool 3000
having an upper attachment section 3002 for attachment to a line
structure (not shown). Below attachment section 3002 is a first
section 3001 having a first motor, e.g., and electric motor. The
motor section 3001 is used to rotate the tool to extend and retract
fixation devices 3004 and 3003 so that they engage the inner
surface of the tubular to be cut. The optical fiber 3005 is located
within the tool and is in optical communication with an optics
package 3006 that directs the laser beam (and may also shape and
focus the beam). The laser beam path then leaves the optics package
and is directed, by beam directing devices, into arm 3008, where it
exist the arm as laser-jet 3009. There an arm opening device 3007,
that moves the arm outwardly from a retracted position to an
operating position. There is provided a second motor 3020 that
rotates the lower section and thus rotates the arm 3008. There is
also provided a protective housing or noise cone 3010. The second
motor 3020 can, preferably rotate the arm in both directions, e.g.,
clock-wise and counter-clock wise. Although not shown, the tool may
have passages and conduits for conveying data lines, and fluids for
forming the laser-fluid jet. Further, the tool may have cut
verification devices, which enable the completeness of the cut made
by the laser to be verified, either real-time during the cut, or on
a separate rotation after the cut. The tool may have an effective
cutting range of from about 24 inches to about 96 inches.
Example 25
[0270] Turning to FIG. 31, there is provided a laser tool 3100. The
tool has a top attachment section 3101 for attaching to a line
structure (not shown). There is provided an electric power line
3012 that is associated with an electric motor 3105 that is
associated with a gear box 3106 for rotating a shaft 3104. There is
further provided an optical fiber cable 3103 that is wrapped around
the shaft 3104, e.g., spiral wrapped around the shaft 3104. There
is a bearing and rotational sealing section 3107 that the shaft and
fiber pass through to a rotating section 3130, that has a laser arm
3109, and protective noise piece 3111. There is a device 3110 to
push the laser arm 3109 from a retracted position 3109b to and
extended position 3109a. In this embodiment, the fiber is wrapped
such that as the lower section is rotated to perform the cut, the
fiber is unwound. In this manner, in this embodiment there is no
beam path that travels in free space across a rotating mechanical
juncture, e.g., a junction where one section is rotating and the
other is not, or where the sections are rotating in different
directions or at different rates.
Example 26
[0271] Turning to FIG. 32, there is provided an embodiment of a
laser tool assembly 3201 located within a tubular 3202. The laser
tool assembly 3201 has a shaft section 3203 that has an anchoring
device 3204, which is expandable, e.g., a spring loaded, to provide
a force to push the shoe against the tubular. The shaft section is
connected to a shoe section 3205. There is provided a motor section
that rotates the shoe section 3205 in the direction of arrow 3206,
relative to the tubular and the shaft section 3203 which do not
rotate. The optical fiber 3207 extends through the shaft 3203 into
the shoe and is optically associated with an optics package 3208,
the laser beam leaves the optics package 3208 and travels along
beam path 3209 to a reflective member 3211, where it leaves the
reflective member 3211 and travels along beam path 3209, to exit
the shoe at nozzle 3210, striking the tubular 3202. In this manner,
a constant distance between the beam exit and the inner surface of
the tubular and be maintained essentially constant, even when
irregularities, or eccentricities are present in the tubular.
Example 27
Multistring Laser Cutting Operational Procedure
TABLE-US-00004 [0272] Step Operation 1. All wells must be clean of
debris in order for internal laser cutting tools to function
properly. Contractor is to use API sized drifts and properly drift
the innerstring of the multistring well prior to the arrival of the
laser cutting system. 2. Lift equipment from the support vessel
onboard the work vessel and sea fasten. Equipment will be rigged up
according to deck spot plan and procedure for rigging. All lifting
operations require a good communication between crew, deck foreman
and crane operator to avoid any hazardous situation (hanging load,
correct rigging, etc.) Sea fastening and verification of the sea
fastening (NDT) will be provided by the client. 3. Hook-up of
umbilical's and hoses. Hook-up of equipment shall commence as soon
as the placement and sea fastening of the equipment is confirmed
and approved by the client. Escape routes shall be identified and
marked. Hook up fiber optics, hydraulics, water and air hoses.
Focus on routing of hoses to minimize trip hazards. Route fiber
optic lines in a manner that minimizes exposure to personnel. Focus
on isolation of equipment to prevent release of stored energy. 4.
Client has filled out and reported the correct cutting depth from
top of the multistring to 15' BML NOTE: Depth is to include an
additional distance from mean sea level to well work deck. 5.
Before running the Internal Laser Cutting Tool down hole, as shown
in FIG. 34, follow deployment checklist and operation procedures
for pre-deployment 6. Clear as much deck space as possible. Place
and secure tool umbilical winch (deployment winch) in-line with the
platform multistring/well to be cut. 7. Check that the laser
internal multistring cutting surface system is ready for operation
8. Connect laser cutting tool to the laser cutting umbilical
(includes fiber optic line, hydraulic lines, pneumatic hoses, and
electrical cables). Once connected perform full laser tool function
test. 9. Connect the Foro gooseneck and injector assembly above and
in-line with the well. Assembly may connect to a operator supplied
I-beam or casing jack platform. Utilizing the vessel crane, hoist
the laser tool and umbilical over to the gooseneck and injector
assembly. Slower lowering the tool down into the top of the well
innerstring. Clamp the injector head assembly to the umbilical for
deployment of the tool to the cut depth. 10. Once the top of the
tool is safely below the top of the multistring and umbilical
secured, proceed to operate the injector head to slowly lower the
umbilical and laser multistring cutting tool down to 15 feet below
mudline. 11. At cut depth, actuate the tools anchors to the firmly
secure the tool to the interior of the multistring. 12. Initiate
gas flow thru the umbilical from the laser surface spread
compressor, this will allow for gas to open the cutting nozzle
orifice and flow evenly over the optic components as well as
provide a proper laser waveguide for efficient internal to external
multistring cutting. NOTE: Do not allow for the gas to shutdown on
the surface at anytime as this will cause debris and sediment to
enter into the optic assembly of the tool and cause failure. 13.
Check surface gas manifold to ensure the umbilical return is open,
once open actuate the cutting tool packers. The gas pressure pumped
down the gas feed line of the umbilical and thru the nozzle beneath
the packers will create a downhole environment conducive to laser
cutting. This will also allow for the innerstring return to be
taken back up thru the umbilical and up the surface for monitoring
cement, mud, seawater and gas returns. 14. Start the laser from the
laser control container located on the vessel deck, monitor the
returns as penetration occurs to check for liquid mud and/or liquid
cement annuli. If voided annulus or fully grouted annulus are
monitored move to step 14 once penetration to seabed occurs If any
of the heavy solids are taken thru the returns, shutdown the laser
but keep air flowing to take the heavy solid return up to surface
and voided annulus occur. Start the laser again and continue with
penetration thru seabed. 15. Confirm laser penetration thru the
wall of the multistring into the seafloor by means of optic
verification 16. Start laser cutting tool head rotation at
pre-specified speed (based on shorebase engineer supplied cutting
times versus multistring outer diameter, number of strings and wall
thickness) 17. Shut the topside valve that controls the return line
in the umbilical 18. Open the secondary air line on the surface
manifold to allow gas flow down thru the return line. This will
allow for additional gas to flow out and thru the cut zone, keeping
a proper cutting atmosphere. 19. Complete 360 degree rotation and
confirm the cut by means of optic verification thru a counter-
clockwise rotation across the previously cut zone. IF not fully
severed continue cutting with laser power at full levels until full
severance occurs. Once multistring has been verified fully severed,
stop the rotation of the tool and release the tools anchor and
packer. 20. Utilizing the injector head slowly retrieve the laser
cutting tool until it reaches the top of the multistring. Gas flow
should still be flowing out of the cutting head nozzle orifice in
order to ensure proper optic cleanliness. Connect the vessel crane
to the tool and umbilical. Securely hoist back to the vessel or
platform working area for maintenance and down-rigging or if
additional wells move the gooseneck and injector assembly to the
next location and repeat Steps 4-19
Example 28
Single Pile Cutting Operational Procedure
TABLE-US-00005 [0273] Step Operation 1. All piles must be clean of
debris in order for internal laser cutting tools to function
properly. Contractor is to properly jet or dredge pile internally
before arrival of the laser cutting tools and systems and remove
any internal centralizers. 2. Lift equipment onboard and sea
fasten. Equipment will be rigged up according to deck spot plan and
procedure for rigging. All lifting operations require a good
communication between crew, Deck Forman and Crane Operator to avoid
any hazardous situation (hanging load, correct rigging, etc.) Sea
fastening and verification of the sea fastening (NDT) will be
provided by the client. 3. Hook-up of umbilical's and hoses.
Hook-up of equipment shall commence as soon as the placement and
sea fastening of the equipment is confirmed and approved by the
client. Escape routes shall be identified and marked. Hook up fiber
optics, hydraulics, water and air hoses. Focus on routing of hoses
to minimize trip hazards. Route fiber optic lines in a manner that
minimizes exposure to personnel. Focus on isolation of equipment to
prevent release of stored energy. 4. Client has filled out and
reported the correct cutting depth from top of the pile to 15' BML
NOTE: Depth is to include an additional distance due to pile batter
angle. 5. Before running the Internal Laser Cutting Tool down hole,
follow deployment checklist and operation procedures for
pre-deployment 6. Clear as much deck space as possible. Place and
secure tool umbilical winch (deployment winch) in front of vessel
railing, closest to the structure and in-line with the platform
piles 7. Check that the laser internal pile cutting surface system
is ready for operation 8. Connect laser cutting tool to the laser
cutting umbilical (includes fiber optic line, hydraulic lines,
pneumatic hoses, and electrical cables). Once connected perform
full laser tool function test. 9. Utilizing the vessel crane, hoist
the laser tool to the pile top deployment frame and secure to the
umbilical to the gooseneck and injector assembly before hoisting
the entire pile top assembly over to the pile. Once the tool and
umbilical are secure, hoist the deployment frame over to the
platform and slowly lower the tool into the top of the pile.
Actuate the deployment frame clamps to secure the frame to pile
top. 10. Once the top of the tool is safely below the top of the
pile proceed to operate the injector head to slowly lower the
umbilical and laser pile cutting tool down to 15 feet below
mudline. 11. At cut depth, actuate the tools stabilizers and/or
anchors to the firmly secure the tool to the interior of the pile.
12. Initiate gas flow thru the umbilical from the laser surface
spread compressor, this will allow for gas to open the cutting
nozzle orifice and flow evenly over the optic components as well as
provide a proper laser waveguide for efficient internal to external
pile cutting. NOTE: Do not allow for the gas to shutdown on the
surface at anytime as this will cause debris and sediment to enter
into the optic assembly of the tool and cause failure. 13. Start
the laser from the laser control container located on the vessel
deck 14. Confirm laser penetration thru the wall of the pile into
the seafloor by means of optic verification 15. Start laser cutting
tool head rotation at pre-specified speed (based on shorebase
engineer supplied cutting times versus pile outer diameter and wall
thickness) 16. Complete 360 degree rotation and confirm the cut by
means of optic verification thru a counter- clockwise or clockwise
rotation across the previously cut zone. Once pile has been
verified fully severed, stop the rotation of the tool and release
the tools stabilizers and anchors. 17. Utilizing the deployment
frame injector head slowly retrieve the laser cutting tool until it
reaches the top of the pile. Gas flow should still be flowing out
of the cutting head nozzle orifice in order to ensure proper optic
cleanliness. Connect the vessel crane to the deployment frame and
securely hoist back to the vessel working area for maintenance and
down-rigging.
Example 29
[0274] Turning to FIG. 33 there is provided a laser cutting tool
assembly having a removable external laser component. Thus, the
laser cutting tool assembly 3300 has a drum 3301 having a side
section for receiving the external laser component 3306. The
external laser component 3306 has a high power laser umbilical
3307, an optics package 3305, a laser beam on a laser beam path
3304 and a nozzle 3303 for forming a fluid laser jet. There is
provided a locking member 3302 that can be rotatably expanded to
engage the inner walls of a tubular to be cut. In this manner a
motor (not shown) rotates the drum, which rotates the external
laser component 3306. External laser components may be specified or
configured for specific diameter tubulars. Thus, the embodiment of
FIG. 33 provides the ability to quickly and easily change the tool
for different size, e.g., diameter tubulars.
Example 30
[0275] Thus, turning to FIGS. 34 and 34A to 34C there is provided
an embodiment of a laser tool. The laser tool has a lower or bottom
section 3416 that rotates. The bottom section 3416 has a returns
intake 3402, a nozzle 3420, that discharges a fluid laser jet 3403,
which is rotated around by the bottom section 3416. The laser tool
has a drive chassis 3405 within an outer chassis housing 3406. The
drive chassis 3404 has a laser beam tube 3441 for transmitting the
laser beam 3404. The drive chassis 3404 has a motor section 3407
for rotating the bottom section 3416. Connected to the drive
chassis 3404 is an electronics chassis 3409, which has an
electronics package 3408 (e.g., motor control, sensor). There is
also provided a pressure sensor 3401. There is a packer 3411 and an
anchor 3410. The tool 3400 has an optics package 3417, a channel
3413 for providing a fluid supply for the fluid laser jet, a
channel 3412 for providing hydraulic fluid to the packer and
anchor, a wireline 3414 for supporting the weight of the tool, and
an umbilical 3415. Turning to FIG. 34B there is provided a
prospective view of the bottom section 3416, and the motor section
3407 showing the motor 3440 and the beam tube 3441. Within the
bottom section 3416 is a prism assembly 3430.
[0276] FIG. 34C is a schematic view of an embodiment of an
integrated umbilical, having an outer member 3450, incorporating a
hydraulics line 3451, a line 3452 for conveying the fluid for the
fluid laser jet as well as acting as a possible strength member,
the line 3452 containing a high power optical fiber in a metal tube
3453, a line 3454 for bringing returns (e.g., waste, cut material)
away from the cut area, e.g., to the surface, and a line 3455 for
providing electric power.
[0277] In addition to these, examples, the high power laser removal
systems, tools, devices and methods of the present inventions may
find other uses and applications in activities such as subsea
beveling; decommissioning other types of offshore installations and
structures; emergency pipeline repairs; cutting and removal of
structures in refineries; civil engineering projects and
construction and demolitions; removal of piles and jetties; removal
of moorings and dolphins; concrete repair and removal; cutting of
effluent and discharge pipes; maintenance, cleaning and repair of
intake pipes; making small diameter bores; cutting below the mud
line; precise, in-place milling and machining; heat treating;
cutting elliptical man ways; and cutting deck plate cutting.
[0278] The various embodiments of systems, tools, laser heads,
cutting heads, nozzles, fluid jets and devices set forth in this
specification may be used with various high power laser systems and
conveyance structures, in addition to those embodiments of the
Figures in this specification. The various embodiments of systems,
tools, laser heads, cutting heads, nozzles, fluid jets and devices
set forth in this specification may be used with other high power
laser systems that may be developed in the future, or with existing
non-high power laser systems, which may be modified, in-part, based
on the teachings of this specification, to create a laser system.
Further the various embodiments of systems, tools, laser heads,
cutting heads, nozzles, fluid jets and devices set forth in the
present specification may be used with each other in different and
various combinations. Thus, for example, the laser heads, nozzles
and tool configurations provided in the various embodiments of this
specification may be used with each other; and the scope of
protection afforded the present inventions should not be limited to
a particular embodiment, configuration or arrangement that is set
forth in a particular embodiment, or in an embodiment in a
particular Figure.
[0279] The invention may be embodied in other forms than those
specifically disclosed herein without departing from its spirit or
essential characteristics. The described embodiments are to be
considered in all respects only as illustrative and not
restrictive.
* * * * *